ELITE FORMING

SYSTEMS

Winning Foundations Start with EMI

 2

SAFETY INFORMATION
This illustration booklet is designed to show you how to handset residential or light com-
mercial foundation forms, using EMI Elite Forming Panels, hardware and accessories. EMI
Elite components and accessories illustrated in this Application Guide have been designed
with safety and performance in mind to help achieve a productive forming operation. All
construction personnel should thoroughly familiarize themselves and comply with the appli-
cable industry standards and safe practices established by the American Concrete Institute,
American National Standards Institute, The Occupational Safety and Health Administration,
and the Scaffolding, Shoring and Forming Institute. Tie spacings shown are for illustration
purposes only; proper spacing must be determined for the individual job. Tie capacities are
detailed on page 21. The maximum allowable pour pressure for the system is 1000 psf.

n Inspect all equipment before using. Never use equipment which appears damaged.
n Be sure that all ties of the right length are used for a specific wall thickness. Intermixed
tie lengths will allow for excessive pressure and possible tie failure.
n Never bend a tie to work around rebar. This can fracture the tie at the breakback point
and reduce load capacity.
n Never beat on the end of a tie to force it through a tie slot. This could damage the
breakback or loop weld and cause a failure. Replace any ties that are bent or compro-
mised before pouring concrete.
n Walers must be used in order to hold forms in accurate alignment.
n Install and position form scaffold brackets or other equivalent means to permit worker
access to areas requiring setting, pouring and stripping operations.
n Brace one side of forms securely against wind loads, impact of concrete placement and
live load of personnel working on forms. Normal bracing is 6' to 10' on center horizon-
tally and each vertical lift of forms.
n Before placing concrete, responsible person(s) should check both sides of the wall to
make sure that all ties are in place and properly connected. Assure that all wedgebolts
are maintained tight and secure in proper positions.
n Standard practices for placing concrete must be followed. Concrete should not be
dropped without the use of an elephant trunk. Vibrating should be limited to 4' below
top of concrete surface, and not used to move the concrete laterally.
n Protective devices such as gloves, safety glasses and steel toe shoes should be worn
during formwork.

NOTE: EMI Construction Products recommends the use of all safety equipment and apparel
such as gloves, safety shoes, safety glasses and hard hats when erecting or dismantling of
Elite Forms.

TABLE OF CONTENTS
2 Safety Information 14 Corners
3 EMI Elite Forming Systems 15 Intersections
4 Panels and Fillers 16 Form Extensions
5 Connecting Panels to Each Other 17 Pilaster Forms
6 Setting Panels on Footings 18 Pilaster Brace
6 Where to Start Panel Placement 19 Capping the Wall Pour
7 Using Fillers Between Panels 20 Stacking Forms
8 Securing Panels with Walers 20 Second Lift Forming
9 Form Alignment 21 Special Purpose Ties
10 Strongbacks for Vertical Strength 23 Curved Walls
11 Scaffold Brackets 25 Wire Tie Gang Forming
12 Forming Footings 26 Stripping Forms
13 Adjustments for Panel Placement

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 3

EMI ELITE FORMING SYSTEMS

In the following pages, you will discover the system techniques, application and versatility
guidelines of the EMI Elite Forming System. There are many components to the Elite
Forming System, including but not limited to:
n Elite panels make up the bulk of any wall forming setup.
n Filler panels are used when the length of the wall is not even 1 foot measurements.
n Form ties are used to keep the forms from spreading when the concrete is poured inside.
n Waler brackets are used to line and straighten the top of the forms.
n Both inside and outside corners.
n Aligners are used to straighten and brace the top of forms in the proper position.
n Scaffold brackets are placed on the forms to allow workers to safely access the top of
walls when pouring concrete.

Form Care for Elite Series Forming System

Forms should be properly cleaned and stored after each use. The frames should be regularly
scraped to remove any accumulated deposits of concrete and plywood facing should be cleaned
and oiled as soon after stripping as possible. Forms should be piled face to face and back to back
for hauling and storage, and should never be thrown or dumped from truck, but handed from
person to person. Forms should be properly inspected for damage before each use.

ELITE PANEL FEATURES

Cleaner Facing, Smoother Pours
Olympic “Classic” 1/2" HDO 5-ply premium plywood features a douglas fir core with a birch
veneer. Provides a strong, long-lasting, smooth pouring surface that releases cleanly, and resists
chipping and nail breakout. Edges are sealed with styrene acrylic sealer, resisting moisture, oil,
alkali and concrete adhesion.
Easier to Handle
Uniquely shaped EZ LIFT handles stay upright for easy grabbing and maneuverability during setup
and take down.
Hold-Fast Rivets
Plywood is machine riveted to the cross angles in a uniform pattern.
Heavy Duty Frame
2" cross angles provide additional panel strength and uniform plywood stress, avoiding ‘pillowing’
found in lower quality panels.
Precision Welds
Deep penetrating continuous welds, ensuring long life under the rigorous stress of panel setting,
pouring and transportation.

CAUTION: DO NOT use handles as a safety belt hook-up or as a connecting point for
bracing, scaffolding or ganged movement of panels.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 4

PANELS AND FILLERS

NOTE: Elite Steel Plywood Forms have a maximum poor pressure of 1000 pounds per
square foot.
Panel and filler handles are designed for use in manually transporting or positioning each
modular panel, and should not be used as a means of attachment or for any other purpose.
Determine the filler width by looking carefully at the end rails. Slots are located in 6" incre-
ments from each end of the end rail for fillers from 10" to 22".

NOTES:
1) Front and rear dadoes align on 12" centers. Three foot high forms have front and
rear dadoes at 6" centers.
2) Handles are added to 20", 22" and 24" wide frames. 5', 6' and 8' length frames
have two handles. 3' and 4' lengths have one handle.
3) There are no wedge bolt slots or dadoes on 4", 5", 6" and 8" filler end rails. All
other end rails have slots and dadoes at 6" O.C. from both ends.

Basic Panel and Filler Sizes

Panels 24" (wide) x 3', 4', 5', 6', 8', 9', 10' (height)
Fillers 4" to 22" (wide) x 3', 4', 5', 6', 8', 9', 10' (height)
Metal Fillers 1", 1.5", 2" (wide) x 3', 4', 5', 6', 8', 9', 10' (height)
Inside Corner (metal) 6" x 6", 4" x 4" (size) x 3', 4', 5', 6', 8', 9', 10' (height)
Outside Corner 3', 4', 5', 6', 8', 9', 10' (height)
Filler Angles 3', 4', 5', 6', 8', 9', 10' (height)
Pilaster Panels 3', 4', 5', 6', 8', 9', 10' (height)
Bay Corners 3', 4', 5', 6', 8', 9', 10' (height)
Hinge Corners 3', 4', 5', 6', 8', 9', 10' (height)

n Please note that custom forms are available to meet our customers’ needs.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 5

CONNECTING PANELS TO EACH OTHER

Wedge Bolts
Wedge bolts are used to connect panels. Two wedge bolts make up a set — use one as a
connecting bolt, the other as a clamping wedge. Pass the first bolt though the panel rail slot,
push the second wedge bolt through the slot of the first bolt. Hammer to tighten securely.

NOTE: DON’T OVERTIGHTEN. Excessive hammering of

wedge bolts may cause damage and require additional labor
during stripping. Use care at all times when striking wedge
bolts with a hammer.

The following five steps illustrate the progressing work cycle for installing each pair of op-
posite panels along with accompanying ties:

Step #1
Position connecting wedge bolts with approximately half of their shaft length projecting
through the side rail slots at the prescribed tie positions (both opposing panels).

Step #2
Place ties over ends of projecting wedge bolts.

Step #3
One at a time, position the next pair of opposing panels in line with the tips of the protrud-
ing wedge bolts, then follow with steps #4 and #5.

Step #4
Push the remaining length of connecting wedge bolts into the adjoining side rail slots.

Step #5
Move the newly positioned panel to close gap between side rails (gap left at step #4). Insert
wedge bolts and tighten to a closed joint position. Don’t hammer them down excessively.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 6

SETTING PANELS ON FOOTINGS

Set panels on lumber sill plates (recommended) or directly on the concrete footing, using a
chalk line. Sill plates are recommended because they provide a flat surface for anchoring
and help you with a positive on-line wall pattern. Nail down panels, making sure the panel
face is flush with the inside edge of plate. Use at least one nail per panel through the nails
holes in the panel.

Add a second sill plate to double the thickness as a way to add wall form height. For
example, an 8' panel setting on a two 1 ½" thick plate would form an 8'-3" wall. This
way is easier than nailing wood on top of the form.

WHERE TO START PANEL PLACEMENT

For most jobs, EMI recommends starting from a fixed point like a
corner or pilaster. Starting at a fixed point reduces the need for fillers
in each wall run, and in most cases is easier and faster to do.
For residential foundations where reinforcing steel is not involved, you
can install inside and outside wall panels at the same time.
6"

First, connect an outside corner angle to the two proper width adjacent
fillers and set the inside corner in place. The width of the outside
8"

corner fillers is predicated by the wall thickness plus the face dimen-
sions of the inside corner. For example, the outside corner fillers for a
10" wall utilizing a 6" x 6" inside corner would be 16" wide. Add this
up correctly and inside and outside panel joints will be aligned for tie
r
lle

placement.
" fi
14

After you install two or three inside and outside panels with ties,
plumb and brace the whole assembly.
Install walers (page 8) as soon as enough panels are erected to cover
the waler lengths. Install alignment bracing also immediately after
installing each length of waler. Then nail down the bottom panel rails.
Foundation walls for heavier commercial and industrial construc-
tion usually require one form side of the wall to be erected first; this
procedure is not covered in this guide.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 7

USING FILLERS BETWEEN PANELS

Ties used on both sides of fillers

There are three types of fillers:

Elite Filler
The simplest solution to unique dimensions. Constructed of the same materials as EMI’s
world-class standard panels, these fillers are available in even increments from 4" to 22" Filler panel
in all standard heights. They connect to adjoining panels using standard wedge bolts.

Long-Bolt 2 nail holes

Elite Metal Filler

Metal fillers are available in 1", 1 ½" and 2" dimensions. The 1" and 1 ½" metal fillers attach
to panels with the adjustable wedge bolt, while the 2" metal fillers use the long wedge bolt.

NOTE: The long connecting bolt is punched with two ¼" holes to accommodate a 16d or
20d nail, or a broken off panel tie end to shorten the bolt for 1", and 1 ½" steel fillers.

Tie
Steel filler

Filler angles

Job-Built Fillers
For bulk heading and special areas auxiliary pipes pass throughs, you can job cut ¾"
plywood and screw or nail to Elite Filler Angles. The filler angles can then be connected to
adjoining panels or standard fillers. Filler angles can also be used to create custom corners
around protrusions, attaching additional paneling to the top of a wall or creating custom
pilaster.
12" max.

Rebar
Pipe

Tie

Filler angles

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 8

SECURING PANELS WITH WALERS

Walers are horizontal braces used to support and align the forms. Typically on an 8’ wall, one waler is needed at the top 6" or 18" dado slot,
where two panels are connected. After waling one side of the wall, typically the outside, wall ties will align the opposite side. Walers can
align straight or curved walls.
When setting panels utilizing either panel ties or flat ties, walers normally function in a form aligning capacity only. This is in contrast with
many job-built lumber methods in which the walers are the main load gathering members to which the wall ties are secured. With EMI Elite,
panel ties or flat ties connect directly to the panel side rails and its lengths terminate at that point. In effect, at each vertical row of ties, the
adjoining side rails function as vertical steel walers; hence, the horizontal add on waler functions as an aligner only.

Wedge Bolts

Z-Tie Holder
The Z-Tie holder can be used with 2 x 4 or 2 x 6 lumber. The Z-Tie holder can also be used
vertically as a strongback. The Z-Tie Holder offers flexibility in placement by inserting the
waler tie in side rail dado slots for connection with two wedge bolts.
Z-Tie Holder

One Piece Waler Clamp

The one piece waler clamp is easy to use and can hook to any rail slot not used for a panel
tie connection. It can hold two 2 x 4s or a single 2 x 4. EMI now offers a one piece 2 x 6
waler clamp.

One piece waler clamp

Gang Waler Rod Assembly

Gang waler rods are wedge bolted to each panel joint. One 2 x 4 is placed on top of gang
waler rod and one 2 x 4 is placed underneath gang waler rod. A gang waler plate is then
slipped onto the gang waler rod and then tightened down with gang waler nuts.
Lapping 2 x 4s and clamping with gang waler plates at two or more panel joints provides
alignment continuity of one length to the other. Lapping 2 x 4s also saves cutting longer
lengths to fit a shorter dimension. For more on wire tie gang forming, see page 25.
Gang Waler Rod

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 9

FORM ALIGNMENT
Attachment plate

Use form aligners to position forms straight and plumb. They are not load bearing and
not designed to resist concrete pressure or any other loads. There are two basic ways to
align forms.
Wedge bolt

Waler

Attachment Plate w/lumber

The first method is to nail lumber, such as a 2 x 4, to an attachment plate, then attach the
plate at the panel at any joint. The other end is nailed to a wooden stake or an EMI Elite
steel stake in the ground. There is no adjustment with this method of form aligning.
Form aligner

Stake

Adjustable Turnbuckle Form Aligner Turnbuckle

The second method is to use an EMI adjustable turnbuckle form aligner, available for top
(panel) or bottom (ground) attachment. Using the turnbuckle nailed to lumber allows the
contractor to adjust a maximum of 6". The end of the lower turnbuckle features a slot for an
EMI steel stake, while the attachment end on the upper turnbuckle fits any panel joint.

CAUTION: Wall and column forms must be adequately braced to safely support
all foreseeable lateral loads associated with wind, eccentric loading, etc. The
materials, quantities, locations and methods of attachment and anchorage of
the bracing design shall be the responsibility of the contractor based on job site
conditions and applicable industry standards.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 10

STRONGBACKS FOR VERTICAL STRENGTH

Strongbacks add vertical strength and rigidity to forms, especially on taller walls or projects
that have stacked panels. Strongbacks assure stacked panels are in a straight line verti-
cally. Strongbacks are typically spaced every 4'; for example at 8' O.C. to 12' O.C. Actual
placement spacing is determined by specific job conditions.
Use a Z-Tie holder with strongback ties or use a strongback J-Hook. The Z-Tie holder
requires an available side rail slot, while the J-Hook attaches to the waler lumber or metal Scaffold bracket

channels already installed. Strongbacks for pipe walered forms are attached with a strong-
back U-bolt. A third strongback method is by using a gang waler rod with gang waler plate
securing 2 x 4s or 2 x 6s vertically. Gang waler rods require available side rail slots. This
method of vertically waling can be used when hand setting or gang forming.
Strongback ties have loops in the same plane and waler ties have loops perpendicular to Strongback
each other.

Waler

Wedge bolts

Strongback
Z-Tie J-Hook
Holder
Waler rod
attachment

Z-Tie Holder J-Waler Hook Gang Waler Rod and Plate

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 11

SCAFFOLD BRACKETS
When crew members need to work at elevated levels, EMI scaffold brackets can be quickly
attached to the forms. These rigid brackets are pre-drilled to allow for a plank floor and
handrail system. The scaffolding system has a weight capacity of 500 lbs.

CAUTION: In accordance with applicable OSHA standards, brackets should not be

spaced more than 8' O.C., and should be in compliance with all applicable gov-
ernmental regulations, codes and ordinances. Do not use scaffolding to support
concrete or equipment and do not attempt to secure scaffold bracket to ties after
forms are removed or in any manner other than as illustrated.

Safety Eye

Safety Eye
The installation of safety eyes on EMI Elite panels allows attachment of safety belts while
working on the forms, though work platforms are recommended and normally provide more
efficient working conditions.

Form

Cantilever bracket
Wedge bolt

Brick Ledge Bracket

The brick ledge bracket connects to panels with wedge bolts and allows quick attachment
of brick ledges and other boxouts, such as beam pockets and window openings. The brick
ledge bracket nailer plate is 3 3/8" long and requires a 2" x 4" as the minimum width fram-
ing member. In most applications, some nailing through the backside of the EMI Elite panel
plywood is required to hold the bottom of the boxout tight against the form face.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 12

FORMING FOOTINGS
Footing Corner Bracket and Stake Plate
Footing pads are easy to form when using the Footing Corner Bracket and the Stake Plate.
Two footing corner brackets, one on top and one on bottom, hold panels firmly, and at
virtually any dimension that your job requires (2" increments). The stake plates are then Corner Bracket
positioned along the top edge of the EMI Elite panels as needed for steel stakes to hold the
forms in place. Either ¾" round or I-beam steel stakes can be used with the stake plate.
Position the stake plates midway between EMI Elite cross members and end rails to provide Stake Plate
access for a stake puller.
All components assemble with standard wedge bolts. The stake plate has two nail holes to
accommodate wood forms.

Stake

Stepped Footing
Standard wedge bolt connections will work if the steps are at 6" or 12" increments. 12" 2 Wedge bolts Nail
increments can include properly installed panel ties due to adjoining tie dadoes. When 6"
increments steps occur, side rail dadoes do not join, hence, flat ties can be installed in the
half tie slot clearance of one side rail dado. Loop ties can be used at a single dado slot as
long as tight form joints are not critical.
2" steel fillers and 4" step fillers have connecting bolt slots every 2", and can be used to
step forms in any 2" increment. For increments other than 6" or 12", it is necessary to use
separate wedge bolts to connect either form side of the filler. Forms can be stepped to any
odd increment utilizing filler angles.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 13

Top of sloped wall

Sloped Footing
The are two different techniques for handling sloped footings. Forms can remain vertical
with triangular footing blocks making the form panels flush to the ground. The other option
is to set the sloped wall perpendicular to the slope and connect the two walls with filler
angles and a custom-cut wedge filler.
Most often, panels are erected perpendicular to the direction of the slope. A wedge-shaped,
job-built filler is used to keeps the form joints vertical and the side rail slots and dadoes
lined up. If the fill-in wedge tapers to exceed a 12" build-up, panels should step down at
12" side rail increments. Triangular
blockout
The job-built, fill-in wedge must be properly braced at 12" side rail increments. Depending
upon specific conditions, the anticipated pressure may warrant waling with additional ties
through the wedge-shaped, job-built form.
Top of straight wall

Sill

Wedge shaped filler

Tie Alignment
Sometimes when panel joints don’t exactly line up with those of the opposite side of the
wall, some flexibility is required. Wire panel ties or flat ties can be safely swung laterally up
to 1" on 8" walls, or up to 2" on 16" walls. Exceeding the 1:8 angle proportions will dimin-
ish the tie strength or cause failure by bending through the tie breakback crimp. Also, the Panel joint
wall thickness dimension will be shortened appreciably.

Tie Swing
The same holds true for vertical alignment, where wire ties can swing up or down up to 1"
on 8" walls, or up to 2" on 16" walls. An example would be where a plate is used under one
form side only, resulting in a bend 1 ½". The key here is to not over bend. Loop tie
only

Vertical movement restricted

by tie slots
Flat tie will not
swing up or down

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 14

CORNERS Outside Corner Steel-ply Side Rail

Outside Corner
Locking wedge bolts are required only at the same elevations as wall tie placement. Make
the connection through the side rail slots adjacent to cross members. Make sure to insert
the lateral wedge bolts first through the outside corner angle, so that the tightening wedge
bolts will bear at the siderail side of each connection.

Crossmember

Bay Corners
Elite Bay Corner components offer the most durable and cost-effective solution for creating
a 135° angle. The inside bay corner has a 3" x 3" face dimension, and the outside bay
corner has a 7" x 7" face dimension. Panel ties connect at adjoining panel joints the same
way they do on standard 90 degree corners. Bay corners can be used horizontally to form
wall haunches and sewage treatment plant “Y” walls. Use steel fillers or job-built fillers to
adjust the bay corners to any thickness of wall.

IBC

OBC

Inside Hinged Corners

Inside hinges help maneuver components into custom angles, and provide architectural
flexibility down to 45°. Once set, the corners require bracing and waling to maintain the
desired angle. Inside hinged corners have a 6" facing.

Outside Hinged Corners

Outside hinges provide architectural flexibility by creating form corners that range from
135° to as sharp as a 5° angle. Once set, the corners require bracing and waling to main-
tain the desired angle. Always insert connecting wedge bolts toward the adjoining panels so
that the maximum swing angle will not be restricted.
In most applications, inside hinged corners are used opposite outside hinged corners.

CAUTION: Due to the inherent flexibility of hinges, corners formed should be waled,
braced and blocked as required. Do not use hinged corners in column applications. 135° max.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 15

INTERSECTIONS
12" thick
Intersecting Walls
When the thickness of an intersecting wall is 12" or less, a single panel or filler will span
the dimension opposite the wall intersection permitting wall tie placement at both inside 6" inside corners
corner form joints.
24"
panel

14" thick

6" inside corners

If the intersecting wall is 13" to 16" thick, one or two steel fillers may be utilized at either
24" side or both sides of a 2' panel to make up the necessary fill-in form dimension.
panel

20" thick
1" metal filler

Pre-bent ties

An intersecting wall thicker than 16" can be formed either by utilizing special pre-bent 24"
panel ties, or utilizing walers plus bracing to support the form joint where ties are not panel
installed.

The pre-bent special tie method is the recommended way, as holding form loads with
internal ties is more dependable than the somewhat unpredictable compression capacity of
external bracing. The load gathered by the waler may also overload the adjacent ties.
Specific job conditions can obstruct forms on one form side of a wall, such as large diam-
eter sewer pipe that must be poured flush to the opposite form face.
When forms are without opposing tie joints, the floating panel joints must be waled and
properly braced.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 16

FORM EXTENSIONS
Form Extension Bracket
The EMI form extension bracket provides a sturdier way to vertically extend your forms. The
extension bracket attaches to the tops of forms using standard wedge bolts. Three holes
are provided for screws to attach 2 x 4 lumber. Lumber will be flush with form face. To
secure extensions, nail lumber across to each side or screw down x-flat ties across the top
of lumber.

Column Forming
Higher pressures due to a faster liquid-head rise are inherent to pouring concrete within
the confined lateral dimensions of a column. All siderails must also resist lateral side-pull
loads that normally are not involved in straight wall panel-to-panel connections. For these
reasons, column outside corners require connecting wedge bolts at slots adjacent to all
panel cross members, plus at slots 6" from each panel or filler end rail, and at slots 6" from
ends of each length of outside corner angle. Form and outside corner lengths are staggered
to eliminate common joints.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 17

PILASTER FORMS
The pilaster form is adjustable in 1" increments for pilasters from 1" to 12" deep. There are
two connecting flanges — one for even-inch increments, such as 2", 4", 6", and the other
for odd increments such as 1", 3", 5", etc.
To determine which end of the flange is even, and which end is odd, measure the space
between the first increment slot and the edge of the form. On one end the measurement
should read 2", and on the other end 3".
If, for example, odd increments are desired, the 2" side of the flange is placed nearest the
wall. For even increments, flip the pilaster form over, placing the 3" end nearest the wall.
Connect pilaster form to fillers using a short wedge bolt horizontally and standard wedge
bolt vertically.

20" Filler

Each pilaster form displaces 3" of wall face dimension adjacent to the wall tie at its flange
to panel connection, therefore the form opposite the pilaster must be 6" wider than the
pilaster being formed. Pilasters are also formed using inside and outside corners with ap-
3" 3"
propriate size fillers.

Shortstopping

14" Filler

Panels or Fillers 1"-24"

Inside Corner

Example of pilaster being formed using panels or fillers and standard corners.

Panel or Filler

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 18

PILASTER BRACE
Pilaster
Form
Pilaster braces secure the protruding pilaster to the adjacent wall, in order to ensure proper
angles. The pilaster brace is needed on only one side of the pilaster.
Two braces are required on the bottom form and one brace on each additional stacked
form. The first brace should be located 6" or 18" from the bottom of the pour. Additional
braces should be located 6" or 18" below the end rail of each form. Avoid interference with
walers or ties.
A panel must be located next to the pilaster form to facilitate brace connection. Attach the
pilaster brace with EMI Elite wedge bolts.

Culvert Form
The culvert form will form the chamfered corners that prevail in many box culverts. On
most chamfer cornered culverts, the roof slab and walls are poured monolithically. Panel
ties are usually required at the horizontal form joint between the culvert form and the top
rail of the inside forms. This means the outside form must also have a horizontal joint at the 3', 4', 5',
same elevation, so that tie dadoes occur at the same staggered positions at opposing form 6' and 8'
lengths
sides. A top tie is then required over the deck to the outside form on the other wall side of
the culvert. The deck forms must be properly shored to support the dead and live concrete
placement loads.

45˚

Form Joint

Culvert Form

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 19

CAPPING THE WALL POUR Form

Bulkheads
EMI Elite panels have plywood faces. Bulkheads can be installed using the same methods
utilized for securing bulkheads in conventional wood forms.
Additionally, bulkheads can be formed using outside corners and wall thickness size filler
or panel.
Outside corner

2" x 4" (example)

Form Plywood Tie

aligner

Battered Walls
A ‘battered wall’ is one in which one or both sides of the wall is leaning in. A ‘single batter’
refers to a wall where one side is straight and the other is leaning in. A ‘double batter’ wall
has both sides leaning in. Ties vary in length from the longest at bottom to shortest at the
top. All framing is the same as normal, except battered walls must to be anchored down to
compensate for up lift during the pour.

Cantilever Bracket
Cantilever brackets are used to suspend an opposing form from the first wall side erected. Cantilever
bracket Long bolt,
This allows a difference in elevation at the bottom of the forms so that a base slab can be S-wedge
monolithically poured with the wall. The capacity is 700 lbs. and maximum spacing is not to
exceed panel length when forms are hung horizontally or 8'-0" when hung vertically.
When the suspended forms are horizontal, a long connecting bolt with S-wedge connects
the cantilever bracket to the form side rail. When the suspended forms are vertical, a
cantilever clip with fast-pin couples the cantilever bracket to the inside forms at the first
connecting bolt slot (6" from the top rail).

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 20

STACKING FORMS
Point wedge bolts down with
Stacked panels locking wedge bolt at underside

Start erecting stacked panels at a corner. Panels and fillers should be stacked on same
sized panels and fillers; this will align horizontal wedge bolt locations.
For best panel face alignment, place the hardware in the first and third wedge slots on each
panel end rail. Place hardware in the middle dado slot when a tie is required. For a more
positive connection, install vertical wedge bolts pointing down, with the locking wedge bolt
at the underside. Most applications will require only one wedge bolt connection on the top
panel to the one below it, through the third end rail slot as measured from last panel set.
Panels at both form sides of a wall should be the same size so that the horizontal stacking
joints are opposite each other.
Panel may be stacked horizontally on top of vertical panels. The same length panel should be
installed horizontally at the opposite side of a wall. The horizontal panels should be selective
lengths so that vertical form joints occur where required for hardware and tie connection,
pilaster forms, corners or any other detail that warrants a common vertical form joint.

SECOND LIFT FORMING

There are several methods to support forms on top of a previous wall pour. One method Anchor
is to embed concrete anchors to the prior pour framework. Remove the first lift forms,
attached a lumber sill to the anchors. This provides a ledge to support the next lift of form-
work. If the ledge is located an inch or two below the previous pour, adequate alignment
between the subsequent pours can be achieved.
Another method is to leave the top tier of the previous forms in place. The second lift of
forms is then erected and supported as a continuation of the first forms. Do not remove the
ties from the top tier of forms when using this method.
Insert & anchor
by others

Gang form

Shear Wall Brackets

We recommend using EMI Elite adjustable shear wall brackets for vertical support of Top of concrete
ganged forms. The bracket is attached with an insert that does not require drilling a hole
through plywood.
The threaded adapter plug is nailed to the plywood face and the insert is screwed on to the
plug. After concrete is placed, and the form stripped, the plug is unscrewed. A fully threaded
high strength ¾" bolt attaches the shear wall bracket to the insert. The adjustable bracket
has a vertical adjustment range of over 2". The guide bolt is a separate item, and must be
ordered when using the adjustable bracket.

Guide bolt

Insert and
anchor bolt

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 21

SPECIAL PURPOSE TIES

Rating According To 2 To 1 Safety

TYPE OF TIE SWL ULTIMATE LOAD A safety factor of 2:1 based on ultimate load is recommended for all forming
applications. Vertical spacing of ties must be such that their safe allowable load is
STD. X-Flat Tie 3000 6000 LBS.
H.D. X-Flat Tie 3500 7000 LBS. not exceeded. Refer to the A.C.I. “Recommended Practice for Concrete Formwork”
STD. Loop Tie 2250 4500 LBS. (A.C.I. 347R-94) to determine vertical spacing and load for each job application.
H.D. Loop Tie 3000 6000 LBS.

Single End Thread

Threaded ties have a special ¼ x 20 thread and require use of a special ¼ x 20 threaded
nut. The keeper bolt creates the spreader action and takes the place of a standard wedge
bolt at each threaded tie panel connection. The tie contains a breakback flat at the threaded
end, and a breakback tool must be used to twist the tie end.

Adjustable Single End Threaded

This tie has approximately 5" of length adjustment available but does not have a breakback
flat at the threaded end. It should only be used in applications where a minimum below
surface breakback is not required; such as, the back fill side of a battered retaining wall.

Threaded Both Ends

Thread at both ends offers twice the range to adjust to job variations in wall thickness and
still retain reasonable assurance in breaking back the tie. Ties with thread adjustment at both
ends are often used to pour a new wall against an existing concrete wall by anchoring it.

Single End Threaded Toggle Tie

The toggle end threaded tie provides for field weld attachment to steel piling, structural
steel, etc. and anchoring to lumber or steel sheathing with an activating wire.

#1 Cone Ties
#1 cone ties and “Z” tie holders are used in conjunction with job-built forms comprised of
¾" plywood, 2" x 4" studs and double walers.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 22

X-Flat Ties
Available in standard and heavy duty capacities, the x-flat tie is one of the more common
methods to tie modular forming systems together.

Loop Ties
Standard and heavy duty loop ties are usually used with modular form systems when a
hand set is in place. Available in a number of configurations.

#2 Cone Ties
#2 cone ties and “Z” tie holders facilitate tying vertical panels opposite job-built forms
comprised of ¾" plywood, 2" x 4" studs and double 2" x 4" walers.

#2A Cone Ties

#2A cone ties and “Z” tie holders will connect vertical panels opposite job-built forms com-
prised of ¾" plywood and double 2" x 4" walers directly against the plywood (no studs).

S-Pilaster Tie
The overall length of a pilaster tie positions opposite wall panels at a given wall thickness.
The breakback flat at one end is moved inboard to establish a breakback point on the tie
ahead of a brick ledge or other type boxout.

Base Tie Connector

The base tie connector will secure either a panel tie or a flat tie to an end rail or a side rail
resting on a footing or where panels butt against an existing vertical surface.

S-Base Tie
The S-base tie has an up-turned open loop at each end which protrudes up through the
bottom rail connecting bolts slots. Wedge bolts insert through the protruding loop ends.

Pre-Bent Ties (many types available)

Unusual wall shapes on occasion warrant the need for special factory pre-bent ties. The
form joint points of connection for pre-bent ties are predetermined and located on the
engineering layout furnished.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 23

CURVED WALLS
5’ radius
Using Elite Panels and Fillers, you can create almost any curved or radius walls. Elite 2'
wide panels will readily form curved walls down to a 15' radius or 30' diameter. Standard
fillers can be used to form smaller radius walls; for example, 8" fillers will form a 5' radius.
8" fillers

Long bolt

Because the outside circumference is larger than the inside circumference, the outside
forms will require 1", 1 ½" or 2" fillers at certain joint intervals to keep inside and outside
panel tie joints opposite each other. You can make curved lumber or plywood walers out of
scrap wood to fit the exact curve for curvature alignment.

Straight lumber walers

You can use straight double lumber walers to establish a curved surface by utilizing the 8"
or 14" gang waler rods, two nuts and two gang waler plates as shown on page 10.

Steel angles, channels and pipe can also be custom rolled to required waler curvature.
Attach custom curved steel pipe and channels to the form with the same connecting hard-
ware methods as straight pipe or channels.
Dimensional lumber such as 1 x 4s and 1 x 6s can be installed flat and flexed to the
desired curvature. These can be laminated in two or more thicknesses for stiffness, with
joints staggered for extended curve continuity.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 24

Curved plates may be made of 2 x 2 lumber flexed to the required curve. For smaller radius
curves, the lumber can be kerfed.
Curved plates can also be cut from 1 x 6, 1 x 8 or 1 x 10 lumber using one side of the cut
for the inside form and the other for the outside form. Small radius plates can be cut from 8’
lengths of plywood.

Depending on the radius, inside form joints will open up at the face. We recommend you
insert wood strips in the opening for two reasons: to prevent excessive grout leakage and
to prevent the natural tendency for form joint wedge bolts to pull panels toward a straight
line. Joints with wood strips also help hold the curve in the desired shape. On larger
radius curves, the face gap may be less than 3/16" inserting strips would not be practical.
Short wood spacer shims at approximate 2' intervals would be sufficient to hold the angle
between adjoining forms.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 25

WIRE TIE GANG FORMING

Large sections of EMI Elite panels and fillers can be assembled first — or ganged together
— then set into place using a crane. Gang form ties are much the same as heavy duty
(wire) panel ties, the difference being the extended loop-to-loop length of the gang form
ties allows you to break off the tie without disassembling the panels. The loop of the tie is
held in position behind the forms by use of the gang form bolt, twist the tie to break it inside
of the concrete, and remove the tie end. With the tie ends removed, the ganged forms can
remain assembled for setting and stripping.

Gang Forms
Ganged forms can be assembled by laying the forms on any reasonably flat surface. Lay 2
x 4 or 2 x 6 lumber under the horizontal joints of the panels. Place the panels face down on
the lumber and insert the hardware in the panel side rails. Connect wedge bolts 6" from the
corners of all panels and 6" from the midpoint of 6' or 8' panel side rails.
Use 2 x 4, 2 x 6 and 2 x 8 lumber for walers and strongbacks for straight gangs. The
combined depth of the lumber for walers and strongbacks should not exceed 12". As an
example, double 2 x 4s might be used as walers and double 2 x 6s or 2 x 8s used as verti-
cal strongbacks. Gang form ties connect directly to the panel side rails with gang form bolts;
therefore, walers and strongbacks are used for alignment of panels only. Since the walers
and strongbacks are not used to contain the concrete pressure, very few are required
compared to job-built lumber forming methods. Walers and strongbacks should be located
so they do not interfere with tie placement. Dado slots are provided at the rear of the panel
side rails and are located at 6" and 18" from the top and bottom of panels for hardware
attachment.
As an example, let us assume that we will build a gang with a 12' height by using 6' panels.
We would align the panels horizontally by attaching 8" gang water rods at the 1'-6", 6'-6" and
10'-6" elevations and place double 2 x 4 or 2 x 6 walers across the panels at these locations.
The walers would be secured with gang water plates, and double 2 x 6 vertical strongbacks
are attached to the walers with one 14" gang waler rod and two gang waler plates.

Form Alignment
Alignment should be installed on one side of a wall only. It is neither necessary nor desir-
able to align both sides. Alignment on both sides can “squeeze” the wall thickness, causing
the condition described previously. Also, it can interfere with proper load distribution on the
ties. Generally, it is best to set and align one side, set the other using spacers and position
ties at top and bottom before securing the other ties.

NOTE: Refer to form alignment section on page 9.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 26

STRIPPING FORMS
Forms can usually be stripped at any point after you remove the walers and connecting
hardware. Usually, it is easier to start stripping forms at an outside corner, or adjacent to
a 1", 1 ½" or 2" filler. Get a bucket or some other container for the hardware so you don’t
lose any. Keep your material costs down; you can reuse what you don’t lose.
Hopefully, you used a quick release agent, like Elite and Greenkote, and the panels release
easily.
We recommend you breakback the ties within two days after stripping. With wire ties, a ½
to ¾ twist will break them back. Flat ties are broken off by a firm hammer blow hitting the
edge of the tie as shown. A blow against the flat side of the tie will bend the tie.

CAUTION: When stripping flat ties, be careful, wear protective clothing and safety
glasses when striking ties with a hammer during the stripping process.

Tie Removal
When the gang is at an elevation above ground, it is recommended that gang form bolts be
removed, ties broken back and the gang detached from adjacent forms beginning at the
bottom and working upwards. This is a safety precaution, which allows the man to get off of
the ganged form at the top of the wall before he releases the final hardware and top row of
ties. At this time, the crane should be attached to the gang life brackets.

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 27

NOTES

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com

 28

526 E. 64th Street

Holland, MI 49423
p. (800) 603-9965 f. (616) 392-7464
emisupplies.com [email protected]

01.09

EMI Construction Products | 800-603-9965 | fax 616-392-7464 | www.emisupplies.com