Optimal plastic solution for the building of the future
Vartdal Plast's new wall system required a plastic component with high functionality, precision and strength. Pla-Mek® has developed and now produces four types of steps that ensure shape, reinforcement and efficient assembly – all in recycled plastic and adapted for fully automated production.
24.01.2025
Optimal plastic solution for the building of the future
Pla-Mek® produces plastic steps for Vartdal Plast’s new wall system
A plastic component with a critical function
When Vartdal Plast developed its new and more robust Wall System, they needed a plastic component with high functionality and strength. The components – known as steps – play a key role in maintaining the shape of the wall elements, securing reinforcement, and simplifying the installation of both interior and exterior cladding.
The solution had to meet strict requirements for precision, mechanical strength, and efficient production. It also had to be injection molded in a fully automated system using recycled plastic.
Technical optimization and efficient production
Pla-Mek® was involved early in the process and worked closely with Vartdal Plast’s technical team. The goal was to develop a plastic step that performed reliably in both the building system and the production flow.
Our contributions included
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Strength calculations and design adjustments
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Moulding simulations to detect potential issues early
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Optimization for injection moulding with good flow and minimal waste
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Production in recycled polyethylene using a fully automated process
The result is a series of components tailored to the system’s technical requirements and a modern, sustainable production line.
Increased strength, easier construction, and shorter build time
Pla-Mek® currently produces four different types of steps for the wall system. These components hold reinforcing bars in place, ensure stability during casting and assembly, and support the attachment of cladding.
The wall elements now feature a concrete core of 200 mm—40 mm thicker than the standard Wall System. This provides a more stable structure that can handle greater backfill and allows for increased spacing between stiffening walls. The new solution also enables higher capacity, broader application, and greater flexibility in construction.
Key benefits
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Faster construction and simplified assembl
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More flexible floor plans for residential and commercial buildings
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Reduced need for internal retaining walls
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Documented sustainability through the use of recycled plastic
“The collaboration with Pla-Mek has been excellent. They’ve followed us closely, delivered on time, and maintained good dialogue with third parties. The product lives up to expectations.
Jarl Sandnes
Salgs- og utviklingsdirektør, Vartdal Plast
Technology in practice
With advanced simulation tools and interdisciplinary expertise, we support our customers early in the process. This helps reduce risk, improve product performance, and ensure a production setup that delivers both quality and efficiency.
Thanks to strong collaboration and a clear division of responsibilities, the project was completed in January 2025—well ahead of the construction season.
Technical expertise delivers real-world results
Our collaboration with Vartdal Plast highlights the value of involving plastic expertise early in the development process. When components are designed in tandem with the end product and production system, the result is solutions that perform better—and last longer.
Facts
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4 step types injection moulded at Pla-Mek®
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Manufactured in recycled polyethylene
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Integrated directly into the wall system
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Optimized for strength, assembly, and production flow