Formeva™ Heavy-Duty Architectural Composite Profiles

Formeva™ Solid Composite Profiles – Engineered for Commercial, Municipal & Infrastructure Applications

Formeva™ Solid Composite Profiles by Green Plank are developed for projects where ordinary timber, standard decking boards or conventional profiles are not enough. Designed for demanding commercial, municipal and infrastructure applications, Formeva™ combines natural fibres, controlled HDPE, application-specific formulations and flexible profile engineering to create long-life solutions for challenging outdoor environments.

From municipal benches and public furniture to heavy-duty walkways, roadside and railway-side walls, canal protection systems, jetties, waterfront developments and selected bridge applications, Formeva™ Composite Profiles can be adapted around the technical and architectural requirements of the project.

Depending on the intended application, Formeva™ can contain approximately 65–70%  NFC  (rice husk or beech hardwood fibre), combined with selected European-sourced prime HDPE or European-sourced recycled HDPE (rHDPE) and functional additives sourced from Europe and/or the USA.

Typical dimensions for Formeva™ Solid Composite Profiles include 140 × 45 mm, 120 × 25 mm and 90 × 30 mm. Special dimensions, cross-sections, surfaces and formulations can also be developed for qualifying projects according to application requirements, engineering considerations and production feasibility.

This makes Formeva™ much more than a standard WPC product. It is a flexible family of Composite Profiles designed for architects, engineers, municipalities, landscape designers, contractors and infrastructure developers who need a material solution built around the project.

Composite Profiles Designed Around the Application

Not every commercial application needs the same profile.

A municipal bench does not have the same requirements as a heavy-duty walkway. A canal-side profile is exposed to different conditions from a railway-side wall. A jetty can require different surface, fixing and structural characteristics from a roadside screening system.

Formeva™ is therefore based on a simple principle: the Composite Profiles should be selected or developed around the application rather than forcing every project to use the same standard profile.

Potential applications for Formeva™ Composite Profiles include:

• Municipal benches and public seating
• Park and street furniture
• Picnic tables and outdoor furniture
• Heavy-duty pedestrian walkways
• Boardwalks and waterfront promenades
• Jetty and marina applications
• Selected bridge-related applications
• Canal-side walkways
• Canal wall-facing systems
• Protective facing for selected canal banks
• Harbour and waterfront developments
• Roadside screening and wall systems
• Railway-side screening and wall systems
• Landscape architecture
• Industrial access areas
• Commercial outdoor structures
• Public-space infrastructure
• Custom project-specific Composite Profiles

For structural, safety-critical, road, railway, bridge, canal or marine applications, the suitability of the exact Formeva™ profile must be established through project-specific engineering, loading calculations, fixing design and applicable technical testing.

Solid Composite Profiles for Demanding Projects

Formeva™ uses solid Composite Profiles for applications where robust profile geometry, substantial material mass, machining flexibility and reliable fixing possibilities are important.

Solid construction can be particularly useful for commercial components that need to be drilled, cut, machined or incorporated into purpose-designed assemblies such as benches, walkways, screens and other public-space installations.

Rather than simply increasing the dimensions of a residential decking board, Formeva™ allows the cross-section and material formulation to be considered together.

This creates greater flexibility to develop Composite Profiles specifically for the loading, span, environment and appearance required by the project.

Standard & Custom Profile Dimensions

Typical Formeva™ Solid Composite Profiles can include:

• 140 × 45 mm
• 120 × 25 mm
• 90 × 30 mm
• Additional dimensions according to project requirements
• Special geometries for qualifying commercial and infrastructure projects

For suitable project volumes, Green Plank can evaluate the development of custom Composite Profiles according to required width, thickness, geometry, surface design, fixing method, support spacing and application.

Custom development is subject to technical evaluation, tooling feasibility, production requirements and applicable minimum order quantities.

Approx. 65–70% Rice Husk or Beech Hardwood Fibre

Depending on the application and required formulation, Formeva™ Composite Profiles can contain approximately 65–70% natural fibre.

The natural fibre component can be selected from rice husk or beech hardwood fibre according to the performance requirements of the product.

This flexibility is important because there is no single fibre formulation that is automatically ideal for every application.

A bench profile, for example, may require a particular balance of stiffness and span capability, while Composite Profiles intended for waterfront or canal environments may have different requirements relating to moisture exposure, dimensional behaviour and installation.

Formeva™ therefore allows the natural fibre, polymer system, additives and profile geometry to be considered together when developing the final product.

European-Sourced Prime HDPE or Recycled HDPE

The polymer component of Formeva™ can be based on European-sourced prime HDPE or selected European-sourced recycled HDPE (rHDPE), depending on the requirements of the project.

Prime HDPE may be selected for applications where a tightly controlled polymer specification is preferred. Selected recycled HDPE can provide an alternative for projects where the use of recycled material is an important part of the material strategy.

For professional Composite Profiles, the important question is not simply whether the polymer is prime or recycled. Consistency, traceability, formulation and suitability for the intended application are fundamental to the performance of the finished product.

Functional Additives from Europe and/or the USA

High-performance Composite Profiles require more than natural fibre and HDPE.

Formeva™ therefore uses selected functional additives sourced from Europe and/or the USA.

Depending on the formulation, these may support fibre-polymer compatibility, processing, UV stability, oxidation resistance, pigmentation and other characteristics required for the particular application.

The additive package can therefore be adapted to the intended service environment of the specific Formeva™ Composite Profiles.

100% Traceability of Declared Raw Materials

For municipalities, infrastructure owners, architects and professional procurement teams, material transparency is becoming increasingly important.

Formeva™ provides 100% traceability of declared raw materials used in the applicable product specification.

This provides greater transparency around the natural fibre, polymer and functional additives used in Formeva™ Composite Profiles and allows professional buyers to evaluate products based on more than appearance and initial purchase price.

Formeva™ Composite Profiles for Municipal Benches

One of the most interesting applications for Formeva™ is the development of municipal benches and public outdoor furniture.

Solid Composite Profiles can be used for seating surfaces, backrests and other suitable components in benches, park furniture, picnic areas and public seating installations.

The wood-inspired appearance creates a warm and natural character, while the composite construction can significantly reduce the need for recurring surface treatments compared with conventional untreated timber.

This is particularly relevant for municipalities responsible for large numbers of benches across parks, streets, schools, waterfronts, railway environments, housing developments and public spaces.

Special Bench Profiles – Up to 1200 mm c/c Support Spacing

For selected bench applications, Green Plank can develop special Formeva™ Composite Profiles with application-specific geometry and formulation engineered for support spacing up to approximately 1200 mm c/c (120 cm).

A wider span between supports can provide important design advantages. It may allow a cleaner bench structure, fewer supporting frames and greater architectural freedom.

However, 1200 mm c/c is not a universal spacing for all Formeva™ Composite Profiles.

Achievable support spacing depends on profile dimensions, cross-sectional geometry, material formulation, expected concentrated and distributed loads, temperature, creep behaviour, fixing arrangement, safety factors and intended use.

A Formeva™ bench profile intended for approximately 1200 mm c/c should therefore be specifically engineered and validated through appropriate structural calculations and/or mechanical testing before being specified for a project.

This approach makes it possible to develop the Composite Profiles around the bench design rather than simply increasing the spacing of a conventional profile.

7 Regular Colours – Plus Project-Specific Municipal Options

Formeva™ Composite Profiles are available in 7 regular colours for applicable product ranges.

Municipalities and architects may also have specific colour requirements for public furniture. For qualifying projects and order quantities, Green Plank can evaluate special colours according to the municipality's design concept and production feasibility.

This can help coordinate benches and other public furniture with surrounding buildings, paving, parks, waterfronts, transport environments or a wider municipal design identity.

Easy-Clean Benches – No Regular Painting, Staining or Oiling

Maintenance is one of the most important considerations when specifying public furniture.

Formeva™ Composite Profiles are designed to be easy to clean and low in routine surface maintenance.

Regular painting, staining or oiling is normally unnecessary. In everyday service, the focus can instead be on periodic inspection and cleaning the benches when required.

This can be particularly valuable for municipalities with hundreds of public installations where repeated surface treatment requires labour, materials and operational planning.

Low maintenance does not mean that the complete installation should never be inspected. Fasteners, supporting frames, foundations and damaged components should still be checked according to the maintenance requirements of the project.

Graffiti Cleaning for Public Environments

Graffiti can be a major maintenance issue for benches, railway stations, roadside infrastructure and public spaces.

Many common types of graffiti may be removable from Formeva™ Composite Profiles using appropriate cleaning products and procedures, depending on the type of paint or marker, exposure time and exact surface finish.

For the best result, graffiti should generally be addressed as early as practical.

Aggressive solvents or highly abrasive cleaning should not automatically be used, as these may affect the appearance of the Composite Profile. Any new cleaning method should first be tested on a small, inconspicuous area and follow Green Plank's applicable cleaning recommendations.

PVC-Free Fire-Performance Formulations Available on Demand

Certain public, railway, transport and infrastructure projects can have specific requirements relating to fire behaviour.

For qualifying projects, Formeva™ Composite Profiles can be developed using PVC-free, project-specific formulations with enhanced fire-performance characteristics.

This provides an option for projects seeking improved fire behaviour without using PVC as the polymer system.

It is important, however, not to describe a profile as simply “fireproof” without supporting classification.

If a project requires a particular Euroclass or other fire classification, the exact Formeva™ Composite Profile, formulation, dimensions and relevant installed configuration should be tested and classified according to the applicable standard.

Once this testing is completed, the verified fire classification can be communicated for that exact product or system.

Composite Profiles for Heavy-Duty Walkways

Formeva™ can also be developed for heavy-duty pedestrian walkways, boardwalks, waterfront promenades and selected commercial access areas.

These environments can experience much greater traffic and loading than a private residential terrace.

For this reason, the dimensions of the Composite Profiles, cross-sectional geometry, support spacing, fixing system, surface design and supporting structure should all be engineered around the expected use.

Where a product is specified as heavy duty, the required load capacity should be supported by appropriate calculations and mechanical testing of the exact Formeva™ profile and installation configuration.

Jetties, Marinas & Waterfront Applications

Jetties, marinas and waterfront environments place particular demands on construction materials.

Formeva™ Solid Composite Profiles can be considered for selected jetty, marina, boardwalk and waterfront applications, subject to project-specific engineering and environmental requirements.

Profile geometry, support structure, fasteners, drainage, slip resistance, temperature movement, wet/dry cycling and expected loading should all be considered as part of the complete design.

For saltwater or other aggressive environments, the exact Composite Profiles, fastening materials and supporting construction should be selected for the relevant exposure conditions.

Composite Profiles for Canal Walls & Bank Protection

Formeva™ can also provide interesting possibilities for selected canal and water-management infrastructure.

Solid Composite Profiles may be considered as components within canal wall-facing, protective facing and selected bank-protection systems.

For example, a project may require a durable facing material between the water environment and a protected bank or engineered supporting construction.

Such applications need to be treated as complete engineered systems. Water pressure, soil pressure, erosion, impact, UV exposure, water chemistry, profile dimensions, fixing and supporting structures all need to be evaluated.

Formeva™ Composite Profiles should not automatically be treated as structural retaining-wall elements unless the exact profile and complete system have been engineered, tested and approved for that function.

Roadside & Railway-Side Composite Profiles

Formeva™ Solid Composite Profiles can also be considered for selected roadside and railway-side screening, wall-facing and barrier-related systems.

The natural, wood-inspired appearance can be particularly attractive where transport infrastructure passes through residential areas, parks, recreational spaces or architecturally sensitive environments.

Road and railway projects may, however, have strict requirements for wind loading, impact resistance, structural performance, fire behaviour, acoustic performance and regulatory compliance.

Where Formeva™ Composite Profiles are expected to provide a structural, safety-critical, fire-rated or acoustic function, that performance must be verified for the complete installed system through the relevant engineering and testing.

Developed for Demanding Nordic Conditions

Outdoor products in Nordic environments can experience rain, high moisture, snow, frost, summer sunshine and repeated temperature changes.

Formeva™ Composite Profiles are developed with these demanding conditions in mind.

The combination of selected natural fibre, controlled HDPE, functional additives and application-specific profile engineering is intended for long-term outdoor use when the product and complete system are correctly designed, installed and maintained.

The most reliable solution is achieved when the Composite Profiles, formulation, substructure, fasteners and installation method are matched to the actual environment and loading conditions.

Natural Colour Evolution During the First Months

Because Formeva™ Composite Profiles contain natural fibres, a small and natural colour evolution can occur during approximately the first six months of outdoor exposure.

This initial weathering behaviour is characteristic of many natural-fibre composite products and can give the surface a more settled, natural and wood-inspired appearance.

The degree of colour development can vary according to colour, formulation, orientation, sunlight, weather and local environmental conditions.

Long-Life Composite Profiles

Infrastructure and municipal materials should be evaluated over their entire service life, not simply by their initial purchase price.

Formeva™ Composite Profiles are developed for long-term use with a focus on robust profile engineering, controlled raw materials and reduced recurring surface maintenance.

The actual service life of any profile depends on its dimensions, formulation, loading, installation, supporting structure, environmental exposure and maintenance.

This is why Formeva™ is approached as a family of application-specific Composite Profiles rather than one universal product for every project.

Application-Specific Warranties – Up to 50 Years

Different Formeva™ Composite Profiles can have different warranty periods because the applications and service environments vary considerably.

A municipal bench, heavy-duty walkway, jetty, railway-side wall and canal application do not experience identical loading or exposure.

The applicable warranty therefore depends on factors including profile dimensions, formulation, intended application, installation and environmental conditions.

Selected Formeva™ Composite Profiles and systems may be available with warranties of up to 50 years, subject to the applicable Green Plank warranty conditions.

The exact warranty should always be confirmed for the selected profile and application before final project specification.

Focus on a Lower CO₂ Footprint

Formeva™ is developed with a focus on efficient material use, natural-fibre utilisation, long service life, traceable raw materials and a lower CO₂ footprint.

Depending on the selected formulation, the use of natural fibres and European recycled HDPE can help make effective use of renewable and existing material resources.

Where public procurement, infrastructure tenders or environmental certification require specific carbon-footprint values or comparative environmental claims, these should be supported by applicable LCA, EPD or equivalent product-specific environmental documentation.

Formeva™ Solid Composite Profiles – Technical Overview

Why Choose Formeva™ Composite Profiles?

• Designed for commercial, municipal and infrastructure projects
• Solid Composite Profiles for demanding applications
• Typical dimensions including 140 × 45, 120 × 25 and 90 × 30 mm
• Custom profile dimensions and geometries for qualifying projects
• Approx. 65–70% natural fibre, depending on specification
• Rice husk or beech hardwood fibre selected according to application
• European-sourced prime HDPE or selected European recycled HDPE
• Functional additives from Europe and/or the USA
• 100% traceability of declared raw materials
• 7 regular colours
• Special municipal colours may be evaluated for qualifying projects
• Ideal for development of benches and public furniture
• Special bench profiles can be engineered for wider support spacing
• Selected bench profiles may support approximately 1200 mm c/c when specifically engineered and validated
• PVC-free formulations with enhanced fire-performance characteristics can be developed on demand
• Potential applications for heavy-duty walkways and boardwalks
• Potential applications for jetties, marinas and waterfront environments
• Potential canal wall-facing and bank-protection solutions
• Potential roadside and railway-side applications
• Easy to clean
• Many common graffiti types may be removable with suitable cleaning methods
• No regular painting, staining or oiling normally required
• Developed with demanding Nordic conditions in mind
• Natural colour evolution during initial outdoor exposure
• Designed for long-term service
• Focus on lower CO₂ impact, subject to applicable environmental documentation
• Application-specific warranties with selected systems available with up to 50-year warranty

Formeva™ – From Municipal Benches to Infrastructure

The real strength of Formeva™ is flexibility.

A municipality may require Composite Profiles for hundreds of benches with a special colour and wider support spacing. A waterfront developer may need a heavier profile for a boardwalk. A canal project may require a special cross-section for protective wall facing. A railway project may need Composite Profiles with project-specific fire-performance requirements. An architect may require a completely different dimension for an urban landscape project.

These applications should not all be restricted by the dimensions and formulation of an ordinary residential WPC board.

Formeva™ allows Green Plank to work with municipalities, architects, engineers, landscape designers, contractors and infrastructure developers to evaluate the appropriate profile geometry, natural fibre, HDPE specification, formulation, colour and dimensions for each project.

Formeva™ Composite Profiles – Built Around Your Project

Formeva™ combines approximately 65–70% rice husk or beech hardwood fibre, European-sourced prime or recycled HDPE, functional additives sourced from Europe and/or the USA, traceable declared raw materials and flexible solid-profile engineering.

The result is much more than a standard WPC board. Formeva™ is a versatile family of Composite Profiles developed for commercial, municipal and infrastructure projects where long service life, reduced routine maintenance, material transparency and project-specific engineering matter.

Planning a municipal bench, heavy-duty walkway, roadside, railway, canal, waterfront, jetty, bridge or other infrastructure project? Contact Green Plank with the required application, dimensions, support spacing, expected loads, installation environment, colour, fire-performance requirements and estimated project quantity. Green Plank can evaluate an existing Formeva™ profile or discuss development of project-specific Composite Profiles and formulations.