7 AFS Rediwall Installation Mistakes (And How to Avoid Them)

AFS Rediwall increases installation speed, structural durability, and NCC compliance, only if installed correctly. In many projects, installation mistakes decrease accuracy, delay inspections, or breach AS3600 guidelines.

At Murs Projects, we’ve seen firsthand how errors like misaligned base tracks, under-bracing, and improper concrete core filling can impact project timelines and inspection outcomes. That’s why we’ve prepared this guide to help you avoid the most common pitfalls and deliver clean, compliant walls every time.

Whether you're a site foreman, contractor, or builder, this checklist of field-tested mistakes and how to prevent them will help you save costs, protect quality, and keep your Rediwall installations up to spec.

Mistake 1: Misaligned Base Tracks

Misaligned base tracks cause panel skewing, joint gaps, and vertical deviation across wall height. This structural walls failure begins when tracks are not correctly positioned or anchored.

If you're unfamiliar with how AFS Rediwall functions structurally, refer to our AFS Rediwall Guide which explains its core components, uses, and typical applications on-site.

Common causes:

• Installing tracks over slab edge

• Uneven grid measurements

• No laser alignment or grid check

How to avoid:

• Set tracks 30 mm from slab edge

• Use laser or string to verify alignment

• Anchor at 300 mm centers

• Keep deviation under ±5 mm across wall

Tip: Misaligned tracks affect interlocking, core fill flow, and bracing geometry.

Mistake 2: Inadequate Bracing or Missed Prop Points

Insufficient bracing causes wall bowing, shifting, or blowouts during concrete filling. These failures increase cost and risk during structural inspection.

Common causes:

• Braces too far apart

• Props unsecured at base or top

• Missing mid-height props on tall walls

How to avoid:

• Use props every 1.5–2 m or per engineer spec

• Clamp braces at slab and panel face

• Verify verticality using plumb bob or laser

• Retension before concrete pouring

Reminder: Bracing maintains vertical position and resists concrete pressure.

Mistake 3: Overfilling Concrete Without Lift Breaks

Overfilling Rediwall cavities increases hydrostatic pressure, causing joint splits, bulging, or blowouts. Lift-based pours reduce stress and allow consolidation.

Common causes:

• Single-lift continuous pours

• Wet mix or uncontrolled slump

• Skipped lift breaks

• Poor vibration

How to avoid:

• Pour in 1.2–1.5 m lifts

• Pause 10–30 minutes between stages

• Use 50 mm flexible hose to fill

• Vibrate each lift with 25–35 mm head

Note: Overfilling never saves time. It creates structural and compliance risks.

If you're not confident managing the core fill process, it helps to have experienced people on-site. Our team of AFS Rediwall installers in Sydney has handled hundreds of pours, we know exactly how to stage each lift to avoid blowouts and meet engineering specs. Call us now at 0420 203 076

Mistake 4: Improper Rebar Sizing or Spacing

Incorrect rebar size or layout reduces load capacity and breaches AS3600 compliance. Every misstep weakens structural continuity.

Common causes:

• Using N12 bars instead of N16

• No lap length or anchorage

• Missing ties or ligatures

• No spacers = poor concrete cover

How to avoid:

• Follow structural drawings exactly

• Use plastic chairs/spacers for cover

• Tie horizontal ligatures every 400–600 mm

• Align vertical bars with starters before pour

Tip: Poor steel fixing leads to concrete shifting rebar during vibration.

Mistake 5: Poor Panel Join Handling

Improper joins at corners or end caps cause leaks, joint movement, or visual defects. Junctions are critical for watertight and structurally sound walls.

Common causes:

• No corner or T-joiners

• Poor cuts around openings

• No PVC adhesive sealing

• Open ends without caps

How to avoid:

• Use AFS factory corner joiners and T-pieces

• Trim with fine-tooth saw only

• Seal with PVC adhesive

• Install caps at all terminations

Reminder: Join integrity determines visual quality and concrete containment.

Mistake 6: Ignoring QA and Compliance Checks

Skipping QA checks results in rework, compliance delays, or failed inspections. Quality control ensures build accuracy and documentation for council sign-off.

Common causes:

• No check for wall plumb or square

• Ignoring brace spacing

• No log of steel placement or joins

• No photo evidence or pre-pour review

How to avoid:

• Assign foreman or QA officer

• Capture photos before core fill

• Verify all tolerances and measurements

Tip: Documentation protects against disputes, delays, and warranty issues.

Mistake 7: Removing Braces Too Early or Skipping Post-Pour Care

Removing braces too early risks misalignment or bowing. Ignoring post-pour care affects appearance and structural durability.

Common causes:

• Removing props before cure

• Not cleaning laitance or splatter

• Ignoring joint movement or leaks

• Skipping top caps or connectors

How to avoid:

• Leave props 24–48 hours depending on mix and weather

• Clean panels with sponge immediately

• Inspect for leaks or defects

• Install top caps or slab connectors as designed

Reminder: Post-pour is your last QA stage before the structure is locked in.

How to Avoid These AFS Rediwall Mistakes?

Avoid Rediwall mistakes by following a verified step-by-step build process. Sequencing and control reduce rework, cost, and compliance risk.

Builder’s Checklist:

1. Align base tracks 30 mm back from slab edge

2. Brace every 1.5–2 m + mid-height for tall walls

3. Pour in 1.2–1.5 m lifts, pause 10–30 minutes

4. Use correct rebar (N12/N16), lap, and spacers

5. Install corner/T joiners, seal with adhesive

6. Log QA checks before and after pour

7. Leave braces 24–48 hrs and clean panel face

Want to see these steps in action? Explore our recent projects to see how our team has installed AFS Rediwall and a range of structural wall systems across Sydney job sites - all built to spec and code.

Why Murs Projects Gets It Right Every Time

Murs Projects installs Rediwall with site-specific QA, engineer alignment, and NCC compliance. We follow every stage - track, brace, rebar, and fill with measurable quality controls.

Every project includes:

• Engineer-confirmed steel fixing

• CodeMark/AS3600 tracking

• Visual and structural QA

• Safe Work Method Statements (SWMS)

We don’t just install walls, we build structures that meet spec, pass inspection, and perform long-term.

Do you need certified AFS Rediwall installers for your next project? Contact Murs Projects today to get a quote or speak with a Rediwall specialist.

Frequently Asked Questions

What is the most common AFS Rediwall installation mistake?

Misaligned base tracks are the most common mistake. They cause skewed panels, joint gaps, and vertical drift.

How do I brace AFS Rediwall properly?

Install props every 1.5–2 m. Clamp each to the slab and panel face. Add mid-height braces above 3.3 m.

What happens if I overfill concrete in one pour?

Overfilling increases hydrostatic pressure. It risks panel deformation, joint failure, or blowouts. Use controlled lifts.

Can I use any rebar size inside AFS Rediwall?

No. Follow engineering specifications. Usually N12 or N16 with correct lap, cover, and ties.

Is it okay to remove braces the next morning?

It depends on curing time and temperature. Best practice: leave braces for 24-48 hours.