The backbone of construction today, providing the essential framework for the majority of concrete structures, is formwork systems. Behind all the panels, is formwork manufacturing. Over time, this process has seen many iterations, from basic wooden molds to evolving into highly engineered steel and composite systems, that have improved the durability, efficiency and reusability. Following in-sync with most manufacturing approaches, what was once a labor-intensive and inconsistent process, thanks to technology has now become a sophisticated and an exact procedure.

Recognising these advancements in design and capabilities, Gael Form took the bold approach of building our own state of the art ISO 9001-certified manufacturing facility from the ground up. Our headquarters in Ballivor sits on a vast 20 acre site, enough space for this to be built right. In the end, the production space came to around 135,000 sq feet and resulted in us building a powerhouse of engineering, craftsmanship and innovation that could serve the formwork needs of clients across Europe and the USA.

At the heart of Gael Form’s manufacturing process is a seamless blend of manual expertise and automation. The installation of manual and automatic cutting CNC machines, allows us to achieve millimeter-perfect accuracy in the formwork components we produce. When it comes to the critical aspect of shaping each piece of steel to the exact specifications, laser cutting, bending and punching technology is utilised here by our team. This is a critical point as it ensures that the panels reach our strength and durability standards. Our implementation of automation throughout this entire flow, not only guarantees consistency and high quality, but also significantly increases speed, reducing wait times for clients.

To hone in on the importance of strength, another very important aspect of formwork manufacturing is welding. Flawless welding is vital and to achieve this every time Gael Form invests in both manual and robotic capabilities to meet structural integrity standards. Our robotic welding results in a consistency that is unmatched and joint precision that can only be achieved through automation while also with the added benefit of doing it with velocity. However, we know that some systems require custom and more intricate designs, which is where our dual approach comes into play and manual welding takes place with our expert team. Either approach results in the same output, a formwork panel that can handle stress without compromise.

We are fortunate that our manufacturing facility plays a role not only in formwork production, but also in our refurbishment and finishing capabilities. You can learn more about our refurbishment services here. Grinding, boarding, painting and galvanizing, though a third party, extends the lifespans of the panels, ensuring that once they leave our facility they are ready to take on the harshest of constriction conditions. 

By Gael Form backing technology innovation across the board, it has directly benefited our clients not just in quality of product but in cost of product too. Reducing waste, time and precision errors, results in delays being avoided due to wait time and formwork systems not being defective, and a cost-effective solution for construction teams that doesn’t eat into project budgets. Building our manufacturing facility from the ground up, means Gael Form has been able to engineer efficiency into every stage of our formwork production. It has truly been an investment that pushed the boundaries of construction innovation and directly benefited every client we work with. To learn more about it, get in touch at info@gaelform.com