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Gates Concrete Forming, Denver, used a CNC router to cut all the 3/4-inch-thick plywood pieces 8- and 4-foot sections in order to stagger joints.

The 105-foot-long wall features multiple curves, so the critical forming element was the radius shaped wales. When complete, the City of Pleasant Hill Welcome Retaining Wall in Pleasant Hill, Iowa, will retain earth and support the stainless steel signage welcoming visitors to the city. The forming contractor set standard form panels plumb then glued the foam inserts against them prior to placing the concrete.

His tables accept CAM files and cut either 3D or 2D objects, while software guided the hot-wire cutter to produce the needed shapes.

Dale Mullikin, an employee of ACH Foam Technologies, Washington, Iowa, created the foam shapes on hot-wire cutting tables. The solution was to block out the shapes using expanded polystyrene foam blocks. The concrete wall would be faced with stone afterward so a rough finish was acceptable. Steve Chmelar, vice president of commercial sales for Carroll Distributing and Construction Supply, Ottumwa, Iowa, says this project for the city of Des Moines, Iowa, included a battered exterior wall (15 degree tilt-back from plumb) with a curving horizontal face in a 1068-foot radius. The Court Avenue Storm Water Pump Station This is best illustrated by three projects. Projects using this technology range from the straight-forward to very complex, requiring the joint efforts of highly trained teams. These combinations enable both enhanced design and precision layout and cutting of form elements. In addition to traditional CAD software, designers use Rhinoceros (Rhino) developed by Robert McNeel & Associates for 3D modeling, in part because it interfaces with other software with such exotic names as Grasshopper, Flamingo, Penguin, Bongo, and Brazil. Designers and architects use 3D CAD to produce design files that are converted to CAM files used to guide CNC routers (and other tools) in order to cut formwork pieces with extreme accuracy-far exceeding what’s achievable by hand. The primary software needed for this new type of concrete formwork is computer-aided design (CAD), used in connection with computer-aided manufacturing (CAM).