How to Install AFS Rediwall: Step-by-Step Guide

AFS Rediwall is one of Australia’s leading structural walling systems, prized for its speed, durability, and compliance. But like any high-performance system, it requires precision in installation to unlock its full structural and aesthetic benefits.

If you're a builder, contractor, developer, or site engineer seeking to learn how to install AFS Rediwall the right way, this guide is for you. Prepared by Murs Projects, a trusted AFS Rediwall installer based in Sydney, this guide outlines the steps of how to install AFS Rediwall, essential tools, safety protocols, and technical details you need to deliver clean, compliant, and high-performance Rediwall installations.

What is AFS Rediwall?

AFS Rediwall is a permanent PVC formwork system designed for rapid construction of concrete walls. It features interlocking modular panels that form a clean cavity for concrete core filling eliminating the need for removable formwork.

It’s widely used in residential, commercial, and civil projects for both load-bearing and non-load-bearing applications.

AFS Rediwall offers a range of performance advantages, including rapid installation, built-in waterproofing, and a clean surface finish that requires little to no rendering. It’s also fire-rated and fully compliant with Australian standards like AS3600 and the National Construction Code (NCC).

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For a detailed step-by-step installation process, check out our comprehensive AFS Rediwall guide.

Required Tools & Materials to Install AFS Rediwall

Before installing AFS Rediwall, it’s critical to ensure that the site is properly prepared and that your team is equipped with the right tools and materials.

Essential Tools:

1. Hammer drill: For drilling anchor points into concrete slabs

2. Torque wrench: To tighten fixings to specified tension levels

3. Laser level or plumb bob: For accurate wall alignment and vertical control

4. Internal concrete vibrator: Ensures proper consolidation during core filling

5. Panel lifter: Helps safely handle and place panels

6. PPE: Personal protective equipment such as gloves, goggles, hard hats, and steel-cap boots

Materials:

AFS Rediwall panels are available in standard sizes like 110 mm, 156 mm, and 200 mm thicknesses

1. Base tracks: Guide and support the wall structure from the base

2. Mechanical anchors e.g. Hilti HUS anchors for securing base tracks to concrete slabs

3. Joiners: Including 90° corners, T-junctions, and internal joiners for wall intersections

4. Panel adhesives and capping profiles: For sealing edges and achieving a clean finish

5. Steel reinforcement bars and ligatures: Inserted into the wall cavity per engineering specifications

6. Concrete mix: Typically 25 MPa strength, as defined by project engineers

Having all tools and materials ready before the first panel is placed helps streamline workflow, minimise delays, and avoid compliance issues.

AFS Rediwall Installation Steps

Installing AFS Rediwall requires following a structured, sequential process to ensure the system performs as designed. Each step involves specific tolerances, tools, and technical details and must align with project-specific engineering plans and compliance standards.

If you're looking for experienced professionals, explore trusted AFS Wall installers in Sydney who understand every step of the process and ensure compliant, high-performance installations.

Take a look at how Murs Projects delivered precise and efficient installation of the AFS Rediwall permanent formwork system on-site in Canley Heights, NSW.

Below, you'll find a complete walkthrough of the installation process.

Step 1: Base Track Installation

Why does it matter? The base track is the alignment control for the entire Rediwall structure. Any deviation at this foundational level will propagate through the panels, compromising plumb accuracy and potentially affecting structural compliance.

Installation Process:

1. Prepare the slab: Ensure the concrete substrate is clean, dry, and fully cured, free from debris or laitance.

   
   

2. Position the track: Install the base track 30 mm back from the slab edge to prevent edge breakout and provide tolerance for finishes.

   
   

3. Clear for rebar: Mark and cut out sections where starter bars pass through the track to allow continuous reinforcement.

   
   

4. Anchor securely: Fix the track using mechanical anchors (e.g., Hilti HUS) at intervals of 300 mm, unless project drawings specify otherwise.

   
   

5. Verify alignment: Use a laser level or string line to ensure the track is perfectly straight and parallel to wall layout plans.

Pro Tip: AFS allows a maximum deviation of ±5 mm across the full wall run. Exceeding this can lead to misaligned panels and increased finishing work.

Step 2: Panel Placement

Why it matters: Proper placement of AFS Rediwall panels ensures structural continuity, joint tightness, and clean vertical alignment. Misalignment here can compromise interlocking and create gaps that affect concrete flow and visual finish.

Installation Process:

Start at corners or control points: Begin by placing the first panel at a fixed corner, expansion joint, or junction, ensuring it's level and plumb.

1. Use a panel lifter: Employ the recommended panel lifter to safely guide each panel into the base track without stress or damage.

   
   

2. Interlock the panels: Slide the next panel into the track and push it into the preceding one until you hear a click from the snap-in join.

   
   

3. Check verticality: Use a spirit level or laser plumb to keep each panel vertically aligned as you progress.

   
   

4. Trim where needed: Cut panels carefully around penetrations (e.g. electrical conduits or plumbing) using a fine-tooth saw, maintaining panel integrity.

   
   

5. Apply end caps and seals: Where panels terminate, use end caps and capping profiles to ensure water resistance and clean edges.

   
   

6. Quality Check: Ensure no panel spacing exceeds manufacturer tolerances. Gaps between panels must be avoided to prevent concrete leakage during core filling.

Step 3: Corners & Junctions

Why it matters: Corners and wall junctions are structural stress points. Installing them incorrectly can lead to misalignment, joint failure, or blowouts during concrete pouring. AFS Rediwall provides a complete range of factory-moulded joiners to ensure accuracy and ease.

Installation Process:

1. Use AFS corner profiles: For 90° external and internal corners, use dedicated corner panels or AFS corner joiners designed to interlock seamlessly.
   

2. Trim panels to suit: Panels adjoining corners or T-junctions should be cut to fit precisely based on the architectural layout and panel spacing.
   

3. Install T-junction joiners: When creating perpendicular wall connections (e.g. service risers, internal walls), use T-junction joiners to maintain continuity and load transfer.
   

4. Seal join interfaces: Apply PVC-compatible adhesive sparingly at joint connections to prevent water ingress and improve panel cohesion.
   

5. Check for plumb and squareness: Use a square and level to confirm all corners and junctions meet layout drawings and don’t deviate from tolerances.
   

6. Common Pitfall: Skipping the use of proper corner or T-junction joiners can lead to concrete leaks and reduce wall integrity at intersections.

Step 4: Bracing & Support

Why it matters: Temporary bracing is essential to keep AFS Rediwall panels plumb and stable before and during concrete core filling. Without proper bracing, panels can shift or bow under concrete pressure, leading to blowouts, misalignment, or non-compliance with structural drawings.

Installation Process:

1. Install adjustable braces: Fix adjustable brace props at regular intervals, typically every 1.5 to 2 metres along the wall run.

   
   

2. Anchor props securely: Props should be mechanically anchored to the slab or base structure, with adjustable brackets fastened to the wall face.

   
   

3. Use plumb lines or lasers: Check each panel’s verticality using a laser level or plumb bob and adjust brace tension accordingly.

   
   

4. Brace corners and intersections: Pay extra attention to bracing at corners, junctions, and changes in direction, where forces can shift during the pour.

   
   

5. Verify stability before pouring: Conduct a full inspection of all props before concrete core filling begins.

   
   

6. Bracing Requirements: For walls above 3.3 m in height, AFS recommends mid-height bracing in addition to base and top bracing to prevent bowing or deflection.

Safety Tip: Only trained personnel should install and adjust brace systems to prevent collapse or injury during high-pressure pours.

Step 5: Steel Reinforcement

Why it matters: Reinforcement bars (rebar) are the core structural element inside an AFS Rediwall system. Correct placement ensures the wall performs under load, resists cracking, and complies with engineering specifications and Australian standards like AS3600.

Installation Process:

1. Review engineering drawings: Follow your project’s structural documentation for bar size, spacing, and overlap details.

   
   

2. Insert vertical reinforcement: Position vertical rebars (e.g., N12 or N16) inside the Rediwall cavity, aligned with starter bars where required.

   
   

3. Place horizontal ligatures: Tie horizontal ligatures (commonly R6 or R10) at regular intervals, typically every 400–600 mm, depending on the wall’s design.

   
   

4. Maintain clear cover: Use plastic spacers or chairs to ensure steel remains centred and properly covered by concrete avoiding corrosion or exposure.

   
   

5. Tie securely: Reinforcement must be tied with appropriate wire to prevent shifting during concrete pour.

Critical Note: Ensure minimum lap lengths, anchorage, and reinforcement details are strictly followed per the engineer’s design, especially in load-bearing or retaining walls.

Step 6: Concrete Core Filling

Why it matters: Concrete core filling is the step that transforms the Rediwall formwork into a structural wall. Proper technique ensures internal compaction, structural integrity, and long-term durability while preventing blowouts, voids, or honeycombing.

Pouring Procedure:

1. Select the right mix: Use engineer-specified concrete, typically 25–32 MPa with 5–10 mm aggregate, ensuring pumpability through narrow cores.
   

2. Pour in controlled lifts: Fill in lifts of 1.2–1.5 metres at a time. This prevents hydrostatic pressure from exceeding Rediwall’s capacity.
   

3. Use a 50 mm hose: Concrete should be pumped using a 50 mm flexible hose, inserted vertically into the cavity.
   

4. Vibrate each lift: Insert a spud vibrator (25–35 mm head) to vibrate each lift every 300–500 mm. Withdraw slowly to avoid segregation.
   

5. Pause between lifts: Allow 10–30 minutes between lifts, depending on temperature and site conditions, to prevent panel bulging.
   

6. Stop short of the top: Finish the final pour 50 mm below the top edge of the panel to accommodate cap finishing or next-level formwork.

   
   

Quality Control:

• Monitor for panel bulging, leaks, or resistance during pour.

• Ensure the vibrator never touches rebar or hits the base track.

Safety Tip: Concrete pouring should always be supervised by a qualified site foreman with a clear communication system between pump operator and wall team.

Step 7: Finishing & Post-Pour Procedures

Why it matters: The finishing stage ensures that your Rediwall installation meets both aesthetic expectations and structural requirements. It’s also critical for preparing the wall to receive finishes, caps, or the next floor level.

Post-Pour Checklist:

1. Clean while wet: Immediately after pouring, wipe down panel faces using a damp cloth or sponge to remove concrete splatter or laitance.
   

2. Inspect joints and alignment: Check vertical joins and wall plumbness after bracing is removed. Look for movement, bulging, or blowouts.
   

3. Leave braces in place: Maintain temporary bracing for 24–48 hours until the concrete has adequately cured, per ambient conditions.
   

4. Install top capping: Fit capping profiles or slab connection hardware where required, especially if this is a retaining or load-bearing wall.
   

5. Backfill or finish: Once fully cured, proceed with backfilling, rendering, painting, or connecting services depending on wall use and design.
   

6. Final sign-off: Conduct a QA inspection and record any adjustments, repairs, or defects before handover.

Surface Tip: AFS Rediwall surfaces often require no rendering or plastering. In many cases, they're ready for direct painting or sealing, saving both time and materials.

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Compliance & Safety Protocols for AFS Rediwall Installations

AFS Rediwall is fully compliant with Australian construction standards, including AS3600, the National Construction Code (NCC), and holds CodeMark certification. It also meets AS1530.4 fire resistance benchmarks, making it suitable for both structural and fire-rated applications. At Murs Projects, we ensure every installation aligns with the structural engineer’s design, reinforcement plans, and bracing requirements.

On site, we follow strict safety procedures including the use of PPE, mechanical panel handling, pre-pour bracing inspections, and compliance checklists. Our team conducts daily briefings, adheres to WorkSafe NSW protocols, and documents each phase of the installation to deliver a safe, high-quality result every time.

Common Mistakes to Avoid When Installing AFS Rediwall

1. Misaligned base tracks leads to cumulative wall misplacement

2. Insufficient bracing causes panel movement during concrete core filling

3. Incorrect concrete mix or slump affects flow, compaction, and wall integrity

4. Lack of vibration results in air pockets and honeycombing inside the wall

5. Poor reinforcement positioning compromises load-bearing capacity

6. Skipping joiners or seals at corners and T-junctions increases risk of blowouts

   
   

Avoiding these common site errors is essential for delivering a compliant, high-performance AFS Rediwall structure.

For a complete breakdown of each mistake — with real-world causes, expert tips, and step-by-step solutions, read our full guide on AFS Rediwall Installation Mistakes and how to avoid them.

Why Choose Murs Projects for AFS Rediwall Installation?

As a specialist in structural wall systems, Murs Projects is trusted by developers and builders across Sydney for precision installation of AFS Rediwall. Our teams are trained in AFS-specific methods, ensuring full compliance with AS3600, NCC, and CodeMark standards on every site.

We handle the entire process from base track layout and panel assembly to reinforcement placement, bracing, and core filling with strict QA controls and engineering alignment. Whether it's a basement wall, lift core, or boundary structure, Murs Projects delivers fast, reliable, and regulation-ready results with every Rediwall installation.

If you're looking for a trusted AFS Rediwall installer in Sydney, Murs Projects offers the experience, compliance knowledge, and on-site precision to get your walls up and done right - the first time. Contact us for a free quote.

Frequently Asked Questions

Can I install AFS Rediwall myself, or do I need a professional?

While Rediwall is modular and easy to handle, proper installation requires knowledge of concrete core filling, bracing systems, and structural reinforcement. For safety and compliance, it's best left to certified installers like Murs Projects.

How high can I build with AFS Rediwall?

AFS Rediwall can be used for multi-storey wall systems, including basements, lift cores, and retaining structures. However, wall height and bracing requirements depend on engineered design and must meet AS3600 compliance.

Is AFS Rediwall waterproof?

Yes. Rediwall panels are made from PVC, offering natural water-resistance making them ideal for below-ground walls, basements, and retaining structures when installed and sealed correctly.

What reinforcement is required inside AFS Rediwall panels?

Typically, you'll install vertical N12 or N16 bars and horizontal ligatures, spaced as per engineering drawings. Reinforcement ensures structural strength and must meet design tolerances.

What’s the fire rating of AFS Rediwall?

AFS Rediwall has been tested to AS1530.4 and can achieve a Fire Resistance Level (FRL) of up to 120 minutes, depending on panel type and configuration.