Formwork 101 - MEVA USA

3. Wall

Wall formwork comes in different types and classifications, as outlined below.

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Conventional
Conventional wall formwork consists of boards or sheets and squared timber. It is flexible, but it can be costly and time-consuming as each component must be assembled on-site. In addition, all of its parts should be made according to the project’s specifications, and they must be nailed together and dismantled again after concreting.

Girder

This is a better version of the conventional formwork. Its components, which usually consist of dimensionally stable girders with two chords and one web, have been standardized to facilitate the assembly of identical and ready-to-use panels. The connection of the panels has also been systematized.

Frame
This type of wall formwork helps reduce labor time since its essential components (forming face, support for forming face, and steel walers) are assembled as one panel. The profile nose of the frames protects the edges of the forming face, thereby extending its lifespan. Connecting devices are used when assembling the frame panels to large-sized units, which are then usually transported by crane.

Crane-independent (hand-set)

This type of formwork can be moved by hand. Because of weight considerations, it is usually made of aluminum or plastic. It can take less concrete pressure than crane-dependent formwork, and is often used in housing and municipal construction projects.

Crane-dependent 

Crane-dependent formwork systems feature a large frame and formwork panels, usually made of steel. As a result, they cannot be moved manually. Since they can resist more fresh concrete pressures than crane-independent forms, they are suitable for the construction of commercial buildings and other extensive infrastructure projects.

Two-sided
As the name implies, two-sided formwork is erected on both sides of the wall. Its formwork ties, which are usually sleeved by spacing plastic tubes so they can be reused, take up the fresh concrete pressure. Push-pull props or large heavy-duty braces are attached to the formwork to align and secure it against wind loads during operation.

Single-sided
Single-sided formwork is used when the concrete has to be poured against existing structures or when builders need to do concreting against a hill or soil. This is why it is most suitable for reconstruction jobs. With this type of formwork system, concrete pressure is transferred from the formwork to the base plates through a support structure. 

Prefabricated
This formwork consists of two prefabricated concrete panels which are assembled in advance, and then transported and filled with concrete on-site. Braces and push-pull props are often used to secure the walls, while working and safety scaffolds are installed with the help of special adapters to make the construction process more cost-effective. Prefabricated formwork helps minimize project duration and labor costs. However, pre-planning is required to ensure that it is transported safely to the site.

Circular
Circular formwork is designed for the construction of curved and polygonal walls. It is also quite useful in the construction of specific concrete structures, such as septic tanks and car park ramps. This formwork system comes in three different types:  

• Round girder – timber spacers are added between the timber girders and steel walers so the formwork can be adjusted to the required radius. 
• Flexible girder – ideal for the construction of curved walls with different radii. It comprises timber/steel girders and a spindle, which allows builders to adjust the formwork to the required radius without having to reassemble the panels.
• Polygonal – existing “flat” frame formwork panels can be refurbished as polygonal formwork by adding supplementary radius panels and rails, allowing builders to minimize their project costs.

Climbing
Climbing formwork is quite useful in the construction of high-rise concrete structures, such as control towers and skyscrapers, because it climbs with the wall. It comprises large wall formwork mounted to a climbing scaffold. There are three different types of climbing formwork:

• Crane-dependent – the climbing unit (scaffold and formwork) requires the use of a crane to reach the next cycle.
• Self-climbing – an automatic climbing system that does not require the use of a crane to reach the next suspension point. Hydraulic rams/pumps lift the scaffold, secondary platform, and formwork to the next pouring cycle. It is ideal for the construction of very tall concrete structures.
• Slipform – a two-sided formwork that slides upwards along the structure being built at a rate of 20–25cm per hour. A system of pipe rods, which is integrated into the already-set concrete, supports the slipform.
   

MEVA is an industry leader offering a wide variety of wall formwork systems that provide highly efficient shuttering, flexibility, and reliability. Our products are lightweight and easy to assemble, and therefore will facilitate the rapid completion of your construction projects. Click here to learn more.

Problems With Other Systems

Other systems, like enterprise resource planning (ERP), computer systems, and barcodes, are all viable – however, we’ve found there’s too much room for human error or system failures.

With an ERP system, you might have a note that says you will use no more than three pieces of material for each unit manufactured. This sounds perfect in theory, but human error quickly gets in the way. People drop, scratch, and otherwise damage items all the time – and those instances often go unreported due to forgetfulness or fear of repercussions. So, more inventory is being used up without any documentation.

In these situations, it’s very common for the manufacturer’s personnel to go to a shelf in search of an item, only to find the inventory has been emptied. This misunderstanding of true consumption is an unnecessary waste of time and reliability for suppliers and customers alike.

It doesn’t matter if personnel use a little more (or less) than expected, with the trigger-response system. The only thing that matters for the consumption-replenishment cycle is how many unopened bundles are left on the shelf.

Raw Material Inventories

On our end, we use the same system of triggers and responses to make sure our coil inventories are correct. Wide master coils are slit into smaller run coils; when we hit the run coil trigger at our steel supplier’s warehouse, we order another master.

This system allows us to be more flexible when buying materials for clients. We don’t hoard inventory, so we can quickly change gears if a client no longer needs a certain product. We can stay close to market pricing as well, rather than gambling with your raw material dollars.

2. Quarterly Reviews

To make sure you’re getting the most out of our supply planning system, we sit down with you and discuss the results. Quarterly reviews are frequent enough to catch issues as they crop up, and make small changes for the next review.

In particular, we like to make sure the inventory levels are spot on. We track all feedback from clients and after one year, we can optimize for your activity levels in each quarter.

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Also, we like to collaborate with our clients to plan the next materials purchase. We discuss:

• How much we have in our inventory

• How much you need

• What the market looks like for your material

• Changes in estimated annual volume

• Pending design changes for your roll-formed parts

• Freight utilization

• Cost-saving ideas

Because we work directly with you, you’ll get exactly what you need for your specific roll forming process.

3. Quality Systems

Dahlstrom Roll Form is ISO 9001:2015 certified, uninterrupted since 1995. This certification indicates that our quality management system meets the International Organization for Standards’ global requirements. 

Proofs of the quality system include:

• On-time delivery percentage (99.5% in 2021)

• Field defect parts per million (3,827 in 2021 – four sigma level is 6,210)

Our customers enjoy the confidence that comes from quick delivery times and a low PPM defect rate.

4. Safety

Aside from being ISO certified for quality management, we’re also SHARP (Safety and Health Acknowledgement and Recognition Program) certified for our safety practices. This certification is the highest recognition given by OSHA for exemplary safety practices.

By promoting safety for our employees, we also promote safety for our customers. Some of our safety precautions include:

• Weekly housekeeping & organization audits:

  Removing clutter and potential hazards from the workspace

• Monthly safety training:

  Bringing in a safety consultant to talk to the whole staff about general safety practices (lifting heavy things, hazardous chemicals, personal protective equipment, etc.)

We are audited by the Department of Labor regularly to maintain our SHARP certification.

5. Cross-Trained Workforce

Our personnel has a vested interest in the success of your product. All of our operators are paid by the acquisition of skill rather than tenure. The faster they learn and the better their skills, the more they get paid. They have every reason to put out the best quality parts for you.

This program includes cross-training for different roll forming machines and client jobs. If something were to happen to the primary employee who runs your product, there’s guaranteed to be another person who understands your tooling costs and part quality requirements.

That means your project will be on time, and you’ll have no unexpected delays on the roll form line or increased costs for idle time.

For more custom formwork systemsinformation, please contact us. We will provide professional answers.