Versatile Steel Moulds for Tall Concrete Columns

The project involved designing steel moulds for casting exceptionally tall concrete columns up to 15 m, exceeding the 8 m limit of standard moulds. Existing systems could not withstand the required pumping pressures (>120 kN/m²) or meet spatial constraints.

Key technical challenges included engineering the moulds for very high internal concrete pressures, creating safe lifting and handling attachments, and stabilising freestanding moulds during pouring. Iterative development drew on temporary works design standards, custom lifting calculations, and bespoke propping and bracing systems. Specialised attachments, such as angled Telehandler adaptors and adjustable corbel configurations, improved adaptability and handling, enabling safe, repeatable production of tall columns.