The Walsall Energy Recovery Facility | Birmingham, United Kingdom

Engineering Excellence: EFCO’s Innovative Formwork Solutions at Walsall Energy Recovery Facility

Birmingham, UK

Waste-to-Energy Infrastructure

The Walsall Energy Recovery Facility in Birmingham, UK, transforms waste management into energy production. This facility will process 480,610 tons of residual waste annually, generating 49 megawatts of electricity to power 90,000 homes. Beyond electricity, the facility plans to capture and export thermal energy (heat) to nearby buildings and industries, creating a combined heat and power (CHP) system that maximizes energy efficiency. This comprehensive solution converts local waste into two valuable community resources—electricity and heat—while supporting the UK’s renewable energy goals and reducing reliance on fossil fuels.

Challenging Structure Requires Specialized Formwork

Careys PLC partnered with EFCO Formwork & Shoring Solutions for the complex primary reception bunker—a massive structure with 105′ (32-meter)-high walls extending 6 meters underground. The design required solutions for tall single-pour walls and large openings. EFCO’s PLATE GIRDER® panels achieved 42′-8″ (13-meter) tall single pours, outperforming competing systems limited to 29′-6″ (9-meter) heights.

Time Savings Through Advanced Panel Technology

EFCO’s PLATE GIRDER® panels, with their 1950 psf (93 kN/m²) pour pressure rating, enabled the construction team to complete the 37′-9″ (11.5-meter) initial wall in one continuous pour instead of two. This eliminated an entire construction cycle, accelerating the schedule and reducing labor costs. The higher pour pressure rating also allowed faster concrete placement within daylight hours, maximizing productivity under the UK’s strict safety regulations.

Innovative Spanning Solutions

For the 82′ (25-meter)-high waste-tipping openings, EFCO’s PLATE GIRDER® spanning system eliminated the need for extensive ground-to-roof shoring. This solution freed valuable ground space for other activities, including crane operations in the main reception pit. The Revit-3D design process ensured the implementation of these complex elements, helping teams visualize and solve potential issues before field installation.

Safety and Efficiency Integration

Heavy-duty access catch brackets installed around the structure provided secure working platforms that supported mechanical lifts (“MEWP”), allowing workers to reach heights safely without ladders. This comprehensive system, featuring extended mesh barriers and stair towers, created a fully contained working environment that met safety standards without sacrificing productivity.

Why Carey’s Chose EFCO

Careys selected EFCO because their Innovative formwork solutions delivered the Lowest in-Place Concrete Cost. The combination of high pour pressure rated panels for tall single pours and spanning PLATE GIRDER® technology eliminated falsework and put the project ahead of schedule. Despite the logistical challenge of mobilizing a 20-ton truck daily for three weeks, EFCO’s service team maintained uninterrupted progress. The 3D Revit design process gave Carey’s complete visualization of complex formwork elements, demonstrating how Quality engineering translates directly to construction efficiency and cost savings on challenging infrastructure projects.