Manufacturing Process

Using a combination of traditional craftsmanship and highly modern technology, we create a positive model that exactly corresponds with the finished exposed concrete surface. With our polyurethane elastomers, especially designed in house for the concrete industry, a negative imprint - the textured formliner - is taken using the finished model. Due to the features of our polyurethane, especially developed for concrete, the formliner can be used up to 100 times. This not only makes concrete design aesthetic and individual, but also economical.

01

The original forms for concrete patterns and some individual patterns are created by hand. They are molded out of plaster or cast of existing patterns. The models for the photo-concrete and single individual pattern are done digitally. An individual design or an image are transferred into a file for the CNC-mill by a computer. It cuts the pattern into board material (Exception: artico).

02

The positive cast is sealed with a release wax and provided with a forming frame. Subsequently, a liquid elastomer is poured onto the cast to produce the formliner.

03

After the synthetic solidifies, the forming frame can be removed. The high elasticity of the formliner enables a reproduction of the pattern that is true to detail and makes it robust enough to be reused multiple times (up to 100 times).

04

The formliner is glued to the mold and waxed with release agents before the concrete is cast.

05

The formliner can be used at the precast plant and in the in-situ concrete.

06

After the concrete has hardened, the element can be removed with no problem. The formliner is ready to use again, up to 100 times depending on the type.