When it comes to the most resource-intensive industries, construction is up in the top percentile. On a daily basis, there are significant amounts of materials that are used and discarded straight after. Some of this waste is just inevitable, however, when looking at formwork panels there is the potential for much longer lifespans. The question isn’t just about reuse, as we are already aware that this is a key feature, it’s about how well materials can be maintained to extend their usability across multiple projects.

In Europe, modern construction teams have reaped the benefits of reusability and sustainability in formwork systems. But this doesn’t directly affect the lifespan of a panel with even the highest quality products on the market facing wear and tear after repeated use. Plywood surfaces become scratched, steel frames rust and warp and minor damages accumulate, coming together to reduce the structural integrity and overall performance of the panels for a team. Degradation in formwork is also accelerated by inconsistent cleaning practices and by the harsh nature of conditions on a construction site, water absorption being an example of an issue that commonly arises. All these factors result in panels losing their efficiency, this then becomes a big problem that can't be ignored because now your formwork systems are producing inconsistent concrete finishes and becoming unsafe to use.

Recognising and responding to these issues around panel's lifespan in the industry, Gael Form introduced its formwork refurbishment service. We designed a process to breathe new life into panels, restoring their strength and usability, while significantly cutting costs for construction companies. For the construction team, instead of replacing formwork systems by having to purchase new panels, they can increase fromwork longevity and maximise their return on investment which also simultaneously reduce their material waste.

The refurbishment process isn’t just a quick fix; it’s a meticulous system that ensures every panel meets the expected standards. When a construction team avails of Gael Form’s refurbishment service here is what is involved…

Evaluation - Understanding the condition of each panel is critical and the process begins with a thorough evaluation of each formwork panel. A deep clean may be required for some, whereas others might need minor repairs to plywood surfaces or structural components. For panels with more severe damage such as weakened steel frames or obvious extensive wear, we will put them through a full service with welding and reinforcement. If the panel unfortunately is categorised as beyond repair then it is disposed of.

Cleaning - To remove residue and debris the panels will undergo intensive cleaning with a 2000 bar high-pressure washer. They are then put through a specialised panel-cleaning machine, ensuring thorough and consistent cleaning across all brands of formwork.

Repair - For panels showing signs of minor wear, a targeted repair process is applied. Small holes, scratches, and surface damage in the plywood are drilled out and sealed with repair insert discs. In this step, if we are required to insert more than four discs per square meter, then in order to maintain safety and structural integrity we will just replace the plywood.

Refurbishment - To restore the steel frame strength we address any cracks, bends, or weaknesses by welding and reinforcing. This is a critical step in the refurbishment service as it ensures that the panels remain structurally sound.

Painting - For companies looking to enhance aesthetic appeal, Gael Form offers an optional painting service. The refurbished formwork can be coated in a company’s preferred colors, giving it a professional finish while adding a protective layer against future wear.

Once the service is complete you are now returned formwork panels that are as good as new. By extending the lifespan, construction teams benefit from significant cost savings, improved sustainability and a smarter approach to equipment management. All these are critical factors of success in this industry and Gael Form is offering a simple and extremely effective solution to achieve these. To discover more about what our refurbishment service can do for you, get in touch here info@gaelform.com