The ShellForm™ System
A factory-integrated, hollow, stay-in-place assembly for monolithic cast-in-place reinforced concrete construction.
The assemblies are highly integrated yet non-structural by design. Structural capacity is provided entirely by site-cast concrete and the reinforcement cage. The structural system and the building code path remain unchanged. Not prefab. Not modular.
- Formwork function and form ties
- Reinforcement, pre-installed per the structural design
- MEP embedment: conduits, boxes, and embeds
- Insulation
- Plaster base and finish substrate
- Optional decorative finish
Assemblies are lifted and set floor by floor and connected through conventional lap splices or mechanical couplers. Project-specified concrete supplied locally is cast monolithically to form the load-bearing core. Open cavities keep every bar, spacing, cover, and embed visible and inspectable before the pour, and every member is QR-traceable from factory to site.
Walls, columns, beams, slabs, and partitions, including L-, T-, and U-shaped corners, below-grade walls, and foundations: one method for an entire reinforced-concrete building.
Electrical boxes are two-part: the base box is cast into the panel face while it is still wet, anchored in the shell itself. After demolding, the box insert is fitted into each embedded base box, and conduit runs are connected and routed per the project's electrical design. On site, wires are pulled through the embedded conduits and connected, and standard local wiring devices, sockets, switches, and their cover plates, are installed at fit-out, the same products as on any conventional project. No chasing and no drilling into the structure.
Both panel faces and the integrated reinforcement cage form in one wet-state sequence on a reconfigurable assembly fixture, followed by a single 8-to-12-hour factory cure. Hollow double-wall production needs two cures and a 180-degree flip; solid precast dedicates a mold per member. No dedicated molds are used.
A typical 3 x 3 x 0.2 m wall assembly weighs under 1 tonne, roughly one-fifth of an equivalent solid element, handled by a standard light-duty crane. The economical road radius runs about 500 to 1,000 km, several times that of solid precast, and standard open-top containers extend delivery overseas; the first European pilot shipped roughly 16,000 km by sea.
Load-bearing prefabrication cannot hold inventory: every unit is structure, engineered for one project. Hollow, non-structural ShellForm™ standard units can be stocked, cut within defined rules clear of connectors, and configured to order. Corners set the shape; straights set the length.
Temporary formwork and ICF-type permanent formwork preserve the structure but stop at formwork or insulation; reinforcement and MEP stay site trades. Twin-wall and double-wall integrate further, but the precast leaves are structural: two cures, a flip, and composite design. Solid precast and volumetric modular carry the deepest factory content, and the product becomes the structure: heavy logistics, joint design, and system-specific approvals. The ShellForm™ System combines deep integration, including reinforcement, with a non-structural product, the conventional cast-in-place code path, and open pre-pour inspection.
The cast-in-place core follows conventional reinforced-concrete code logic and has been delivered at scale in zones up to 0.30g. The approved cast-in-place design is the only design: assemblies are production divisions of the issued drawings, so there is no parallel structural regime to re-engineer market by market.
Every unit leaves the factory with a QR identity tag resolving to its own record: member type, position on the plan, a per-component bill of materials, and linked production QA data.