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Formliner Project Design: Working With Seams, Corners and Edges

As mentioned in a previous post, in order to achieve an overall balanced project design it is important to consider formliner pattern dimensions, especially when planning for unavoidable joints, boxouts and corners in the finished surface.

When your design vision includes a pattern that does not fit the proposed area there are options to allow you to specify the pattern you prefer while maintaining aesthetic appeal on your wall, bridge or other architectural project.

Rustication
Rustications or reveal strips are recommended at formliner butt joints. This not only accentuates the pattern, but also eliminates the need to produce a perfect pattern joint. This can be especially useful when trying to align ribbed and vertical patterns, as these types of patterns combined with the normal formliner manufacturing tolerances of +/- .25” create a challenge to align everything.

It is recommended that rustication be applied as a closure on the top of a pattern and sealed with foam tape.

Boxouts

There are two methods of forming boxouts: (1) permanently modifying the formliner, and (2) applying a closure to the face of the formliner.

  1. Boxouts by modification require that the formliners be cut to accommodate the boxouts. The location of the pattern features should be determined before fabricating the required boxouts.
  2. Boxouts by closure do not require that the formliners be cut. The required boxouts are placed over the formliner, and materials such as caulking or foam tape are used to fill the voids between the boxouts and the formliner surface. The materials used are dependent on the configuration of the formliners and the concrete pressures. Access through the boxout should be considered when box out exceeds 2′ in width.

Corners

There are two methods of forming corners: (1) permanently modifying the formliner, and (2) applying a closure to the face of the formliner.

  1. Corners by modification require that the formliners be mitered to accommodate the corners. The location of the pattern features should be determined before mitering the required corners.
  2. Corners by closure do not require that the formliners be cut. A smooth reveal is used at inside or outside corners to simplify corner formwork construction and minimize pattern misalignment at the corners. Custom Rock Duraform (elastomeric) formliners are shipped on pallets approximately 4’ wide by 8’ long and our V-Lite (plastic) formliners are nested and shipped on pallets approximately 4’ wide by 10’ long.

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