Plaster panel models in CAST cast from the same fabric formwork rig.
PANELS
CAST has developed methods for constructing precast concrete panels using a reusable flat sheet of fabric as a mold. Full-scale trials of these methods have produced a series of 2.4m x 3.6m (8 ft. x12 ft.) prototype casts of a wide variety of unique precast panel designs.
The basic method uses a flat fabric sheet (we have used inexpensive polyethylene or polypropylene fabrics) held, and generally stretched, in a steel frame. A pattern of supports is placed beneath the fabric to give it areas of support. The fabric deflects downwards between these supports when it is loaded with wet concrete. The pattern of the supports may be varied or altered as desired, while using the same sheet of fabric for successive casts.
Concrete panels cast from flexible fabric molds can, themselves, be used as molds to cast “Invert-cast” panels. Using a fabric-cast panel as a mold produces concave, shell-shaped, surface geometries that can reduce the volume of concrete used in the panel by reducing its thickness (and weight).
The construction process for producing both direct-cast and invert-cast panels using fabric molds is explained in more detail in the PDF article “Fabric-Cast Panels” (see Resources below).
Resources:
