A concrete wall forming system is a reusable form (a large mold) that allows a manufacturer to create sections of a concrete wall. Columns connect the sections to form a continuous wall.
At AFTEC, we manufacture two main types of concrete wall form systems: the StoneTree® system and the SoundTec®.
The StoneTree® system casts both the column and panel in the same mold, saving builders both time and money. Since it requires only one mold, both builder’s equipment cost and construction time are decreased significantly. These walls duplicate the look of stone wall formwork yet are much sturdier and easier to build.
The SoundTec® system casts panels that incorporate materials to reflect or absorb sound. These panels come with separate concrete or steel support columns and are also available in various sizes and widths. We can design a SoundTec® wall-forming system in a variety of textures to create an aesthetically pleasing appearance.
We also create custom concrete forming systems to meet the needs of builders who require specialized forms to create walls with properties to meet various needs, be they functional or aesthetic. Like the StoneTree® and SoundTec® systems, we use only the finest materials to make these forms; we build them to last. Customers who want to explore custom wall systems meet with our engineers, who will design a custom form that is easy for builders to use.
Why Is a Concrete Wall Forming System Better?
Quick construction: Compared to traditional concrete wall-building, concrete wall forming systems allow builders to create several sections at a time. These sections are easy to install, even with fewer workers.
Takes weather out of the picture: During inclement weather, a builder can move a concrete wall forming system under a roof or into an enclosed area. Work can continue, despite the weather—unlike with the traditional wall-building process. A StoneTree® system produces walls that can even resist most hurricanes.
Even energy absorption: Despite builders’ best efforts, traditional concrete walls lack energy-absorbing consistency since they are not mass-produced. This causes them to absorb energy at different rates, causing them to crack at various temperatures. Wall form work crafted from a mold results in precast sections that all with the same properties. Temperature fluctuations, therefore, will not have as much effect on walls built using concrete forming systems.
A variety of design choices without the cost or hassle of natural stone: Natural stone or brick walls are beautiful, but their structural integrity is tough to maintain. Mortar becomes loose with the passage of time as water, wind, and use take their toll. For a single-family home, that may not be much of an issue. For walls surrounding office buildings, apartment complexes, or large facilities, that can be a huge problem. There is simply too much of the wall to maintain. With a concrete wall forming system, you can have the best of both worlds. Our wall formwork comes in a wide variety of natural-looking stone and brick designs that could fool even the fussiest designer. And it’s a whole lot more cost-effective.
Quick construction time: With precast wall sections, what could take days only takes hours. For builders who want to end up casting the lowest bid yet provide top-quality work, these concrete forming systems are the answer.
Ability to reflect, absorb, or block sounds: When they use a concrete wall forming system, builders can incorporate acoustic materials into the construction. Instead of incorporating these materials in a multi-step process, one section at a time (as you would with manually constructed walls), a builder can incorporate them in several sections at once during the molding process.
Reusable: Concrete wall forming systems use a rugged mold that builders can use time after time, unlike the temporary frames that manual walls require. This saves time, money, and resources.
Mold- and insect-resistant: Sturdy wall form work from a mold is more resistant to insects (who can crawl into tiny cracks in other types of walls), mold, mildew, and rot than either natural stone, brick, concrete block, or manually built concrete walls.
Better heat and cold protection for buildings inside the wall: A wall built with a concrete wall form system has greater thermal mass, more insulating power, and lower air filtration. For walls enclosing office complexes or residential developments in areas where the weather fluctuates greatly, this kind of wall formwork can reduce the energy it takes residents to heat or cool their offices or apartment buildings.
How It Works
Preparation: A concrete wall forming system uses a specially constructed pit, into which a builder lowers the mold. Each mold has a set of easily interchangeable liners, which change the appearance of the finished product: stone-look walls, brick-look walls, smooth, or even a customized appearance. Molds can also be constructed to allow for openings at various locations across the wall. At the site, workers install caisson footings for the wall, providing strength, stability, and ease of installation.
The molding process: Next, builders pour concrete into the mold from above, allowing the wall to form vertically. This allows air to move between the sections of the mold, drying it more evenly. Vertical molding also allows both sides of the wall form work to have decorative features.
Removal and setup: After the sections are formed and dry, builders use a crane to pull the wall sections out of the mold and move them into place along the construction site. Alternatively, builders can manufacture these sections at their own facility or have them made at a precast plant. If so, they use the crane to load the sections onto a truck, which can then deliver them to the construction site.
With AFTEC’s efficient concrete forming systems, an on-site three-person crew, including a foreman, can manufacture and install a 90-foot section of a six-foot wall within a single day. With a well-trained crew using an AFTEC concrete wall forming system, a construction company can have a superior wall in half the time with only half the lifting equipment needed for traditional solutions.
To discover more about the advantages of AFTEC’s concrete wall forming systems for your construction company, research our customers’ most often-asked questions and get in touch with our knowledgeable customer care team for a consultation.