The Precast Show NPCA 1 precast.org/education FORMLINERS: BEST PRACTICES AND ENDLESS POSSIBILITIES Ray Clark, US Formliner precast.org/education WELCOME! precast.org/education WHAT IS A FORMLINER? • A finished material used to impart texture or patterns onto concrete precast.org/education TWO COMMON TYPES OF FORMLINERS • Polyurethane • 10-use, 50-use, 100-use • Plastic • Single-use, low multi-use precast.org/education POLYURETHANE FORMLINERS • Benefits: • Re-usable • Enhanced textures and patterns • Flexible • Larger sizes = less seams precast.org/education HOW IT’S MADE 1 2 3 4 5 6
Transcript
The Precast Show
NPCA 1
precast.org/education
FORMLINERS: BEST PRACTICES AND
ENDLESS POSSIBILITIESRay Clark, US Formliner
precast.org/education
WELCOME!
precast.org/education
WHAT IS A FORMLINER?
• A finished material used to impart texture or patterns onto concrete
precast.org/education
TWO COMMON TYPES OF FORMLINERS
• Polyurethane• 10-use, 50-use, 100-use
• Plastic• Single-use, low multi-use
precast.org/education
POLYURETHANE FORMLINERS
• Benefits: • Re-usable
• Enhanced textures and patterns
• Flexible
• Larger sizes = less seams
precast.org/education
HOW IT’S MADE
1 2
3 4
5 6
The Precast Show
NPCA 2
precast.org/education
CAD drawings
are
developed.
These are
converted
to 3D models
for
approval.precast.org/education
CNC Milling
machines work
24 hours a day
cutting the
design onto
wood to
provide a
perfect replica.
precast.org/education
CNC work
completion.precast.org/education
The master
mold surface
is sealed.
To create large
panels, several
parts can be
joined
together.
precast.org/education
Master mold is
framed.
Constant
quality checks
ensure positive
results.precast.org/education
Finished
master is
sprayed or
brush coated
with mold wax.
7 8
9 10
11 12
The Precast Show
NPCA 3
precast.org/education
Liquid
polyurathane
rubber is
poured onto
the master and
allowed to self
level, avoiding
air entrapment.precast.org/education
Back surface is
leveled.
precast.org/education
After 24 hours
the liner can be
removed.
A tube is used
to roll the liner
and avoid
stress to the
new liner.precast.org/education
Final QC
checks are
made.
precast.org/education
PLASTIC FORMLINERS
• Benefits: • Less expensive
• Some types can be re-used
• Shorter lead times
precast.org/education
HOW IT’S MADE
13 14
15 16
17 18
The Precast Show
NPCA 4
precast.org/education
PLACEHOLDER FOR PLASTIC FORMLINER VIDEO
precast.org/education
WHO DECIDES WHAT TYPE OF FORMLINER TO USE?
• Designer
• Owner/Developer
• Construction Manager
• Precaster
precast.org/education
PARTNERING WITH YOUR FORMLINER SUPPLIER
• Get the formliner supplier involved in the process as early as possible
• Design phase – discussions with the designer on any apparent limitations from a formliner production standpoint or considerations to be made when using with precast concrete
• Bidding phase – ensure all questions from the formliner supplier are addressed with the precasterand designer prior to submitting bid
• Ordering phase – place order with formlinersupplier earlier, rather than later
precast.org/education
WHAT TO CONSIDER WHEN PLACING FORMLINER ORDER
• Multi-use or single-use formliners
• Shop drawings from formliner supplier
• Proper orientation of pattern
• Wood embedded or loose formliners
• Materials for adhering to production table
• Proper release agent
• Storage area for formliners when received
• Proper application instructions provided
precast.org/education
RECEIVING AND USING YOUR FORMLINERS
• Proper storage prior to use
• Lay out and relax
• Review application instructions with production team
• Give the formliners a “once over”
• Apply proper release agent and amount
• Use correct rebar chairs and spacers
• After concrete stripping, check for any defects in the concrete and formliner
precast.org/education
HOW NOT TO STORE FORMLINERS
19 20
21 22
23 24
The Precast Show
NPCA 5
precast.org/education
RELEASE AGENTS TO AVOID
• Diesel or any other type of fuel
• Vaseline
• Cooking spray
• Motor vehicle oil
• Only use release agents specifically formulated for architectural concrete
precast.org/education
ADHERING FORMLINERS TO PRODUCTION TABLE
precast.org/education
PREPARING FORMLINER FOR GLUING
precast.org/education
GLUING FORMLINER TO TABLE
precast.org/education
FORMLINER SET FOR CASTING CONCRETE
precast.org/education
MAKING STOP-OFFS
25 26
27 28
29 30
The Precast Show
NPCA 6
precast.org/education
CUTTING FORMLINERS
precast.org/education
HOW TO USE FORMLINERSFOR A CURVED AREA
precast.org/education
STRIPPING CONCRETE FROM FORMLINERS: WHAT NOT TO DO
precast.org/education
STRIPPING CONCRETE FROM FORMLINERS: WHAT TO DO
precast.org/education
REPAIRING FORMLINERS
• Polyurethane formliners can be repaired • Sometimes at the precast manufacturer
• In worst case situations, formliners will need to be sent back to the formliner manufacturer for repair
precast.org/education
31 32
33 34
35 36
The Precast Show
NPCA 7
precast.org/education
STORAGE OF FORMLINERS AFTER JOB COMPLETION
• Keep them out of direct sunlight
• Keep them out of inclimate weather
• Store in containers or under black sheeting
• Long-term storage when stacked on top of each other may cause damage to surface texture or pattern
• Loose formliners can be rolled and stored
precast.org/education
THE 7 DEADLY SINS TO AVOID WHEN USING FORMLINERS
1. Not using the proper release agent, not enough release agent, or too much release agent
2. Small debris left on production table or formlinersthat causes a dimple in the concrete
3. Improper storage of formliners
4. Cutting formliners
5. Improper layout or mating of formliners
6. Aggressive stripping of the concrete from the formliners
7. Incorrect adhering of formliners to production table
precast.org/education
QUESTIONS?
precast.org/education
UNIQUE USES OF FORMLINERS
precast.org/education precast.org/education
37 38
39 40
41 42
The Precast Show
NPCA 8
precast.org/education precast.org/education
precast.org/education
…to Concreteprecast.org/education
precast.org/education precast.org/education
Restored
Bomb
Damaged
Museum
43 44
45 46
47 48
The Precast Show
NPCA 9
precast.org/education precast.org/education
Design is re-
created
precast.org/education
And cast in
conceteprecast.org/education
precast.org/education
History is
preserved.
precast.org/education
PROJECT FOR LEGOLANDPREPARING TO CARVE MASTER MOLD
49 50
51 52
53 54
The Precast Show
NPCA 10
precast.org/education
CARVING MASTER MOLD
precast.org/education
RELEASE OF FORMLINER FROM MASTER MOLD – 2 TONS
precast.org/education
PRECAST ELEMENT
precast.org/education
THIN PRECAST
precast.org/education precast.org/education
55 56
57 58
59 60
The Precast Show
NPCA 11
precast.org/education precast.org/education
precast.org/education precast.org/education
precast.org/education precast.org/education
ENDLESS POSSIBILITIESWHAT’S NEW?
61 62
63 64
65 66
The Precast Show
NPCA 12
precast.org/education
PHOTO CONCRETE
• High-resolution photo is used
• Photo transferred to special software and converted to 256 shades of gray
• CNC used to mill image onto MDF (master mold)
• Master mold is used to cast photo concrete formliners
