Symons Architectural Form Liners Specification

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SECTION 03121

ARCHITECTURAL FORM LINERS

For best results, display hidden notes to specifier.

** NOTE TO SPECIFIER ** Symons Corporation, plastic and elastomeric architectural form liners.
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This section is based on the products of Symons Corporation, which is located at:
200 East Touhy Avenue
Des Plaines, IL 60018
Tel: (847) 298-3200
Fax: (847) 635-9287
E-mail: info@symons.com
Website: www.symons.com
.
Symons Corporation offers the widest selection of form liners and architectural concrete forming systems in the industry. This section covers more than 30 standard form liner textures in four different form liner materials. Material can also be supplied to meet custom specifications upon request.
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PART 1

GENERAL

1.1

SECTION INCLUDES

** NOTE TO SPECIFIER ** Select paragraphs below applicable to project.

Plastic form liners.

Polyurethane form liners.

1.2

RELATED SECTIONS

** NOTE TO SPECIFIER ** Delete sections below not relevant to this project; add others as required.

Section 03120 - Architectural Cast-In-Place Concrete Forms.

Section 03300 - Cast-In-Place Concrete.

Section _____ - _______________________________.

1.3

SUBMITTALS

Submit under provisions of Section 01300.

[ Product Data ]: Manufacturer's catalog data, detail sheets, and specifications.

1.4

DELIVERY, STORAGE, AND HANDLING

Inspect the materials upon delivery to assure that specified products have been received.

Store form liners in closed shipping crates until needed on work site; protect from sunlight, dirt, and debris.

Once attached to formwork, store form liners on edge. Avoid striking face with heavy, sharp, or heated objects that could cause permanent damage.

PART 2

PRODUCTS

2.1

MANUFACTURERS

Acceptable Manufacturer: Symons, which is located at: 2400 Arthur Ave. ; Elk Grove Village, IL 60007; Toll Free Tel: 800-800-7966; Tel: 847-298-3200; Fax: 847-635-9287; Email: request info; Web: www.symons.com

Requests for substitutions will be considered in accordance with provisions of Section 01600.

** NOTE TO SPECIFIER ** Delete paragraph above or below; coordinate with Division 1 requirements.

Substitutions: Not permitted.

Provide all architectural form liners from a single manufacturer.

2.2

MATERIALS

** NOTE TO SPECIFIER ** Select form material(s) from the four paragraphs following, deleting those not required for the project. Select on the basis of the specific application and the number of uses required.
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Generally, SPS plastic is an inexpensive alternative for single use applications. Thermoformed ABS plastic form liner exhibits good impact resistance and includes an ultraviolet inhibitor allowing 5 to 10 reuses. Dura-Tex(R) form liner is an economical polyurethane allowing stripping from complex designs and up to 40 reuses. Elasto-Tex(R) is a premium polyurethane form liner exhibiting exceptional durability, tear strength, flexibility to allow stripping from slight undercuts or complex designs, and resiliency to maintain pattern details; Elasto-Tex form liners allow up to 100 reuses. In all cases, reuse is subject to pattern configuration, proper handling, and job site conditions.

SPS Plastic: Polystyrene.

ABS Plastic: Premium quality ABS.

Dura-Tex(R) polyurethane: Polyurethane Elastomer.

Elasto-Tex(R) polyurethane: Premium Polyurethane Elastomer.

Form Release: Liner Kote(tm) or Magic Kote(R), as specified hereinafter.

** NOTE TO SPECIFIER ** Include subparagraphs below as required for the project. Consult manufacturer for types and brand names of required materials.

Silicone Calking: __________________________________.

Adhesive: ___________________________________.

Solvent: ___________________________________.

** NOTE TO SPECIFIER ** Retain either or both of the two subparagraphs below for attachment of form liner to plywood. Nails may enhance the finished look of wood patterns.

Staples: 9/16 inch () or 3/4 inch (), depending on pattern thickness.

Nails: ________________________________.

** NOTE TO SPECIFIER ** Consult manufacturer for additional materials required for the specific installation and insert below.

_______________________________________________.

2.3

PRODUCTS

** NOTE TO SPECIFIER ** Select standard product(s) and pattern(s) from paragraphs and subparagraphs below, deleting those not required for the project. Refer to manufacturer's catalog or actual samples for representations of products and patterns. Note that, as standards, not all products and patterns are available in all materials.

Wood Pattern Form Liners:

4 Inch Wide Aged Cedar.

P/C 30706 (SPS), no reveal.

P/C 30480 (ABS), no reveal.

2 Inch Wide Aged Wood.

P/C 30705 (SPS), no reveal.

P/C 30479 (ABS), no reveal.

4 Inch Wide Aged Wood.

P/C 30703 (SPS), no reveal.

P/C 30249 (ABS), no reveal.

Barnwood.

P/C 30613 (Dura-Tex), no reveal.

P/C 30913 (Elasto-Tex), no reveal.

4 Inch Variable Depth Cedar.

P/C 30618 (Dura-Tex), no reveal.

P/C 30921 (Elasto-Tex), no reveal.

6 Inch Wide Cedar.

P/C 30605 (Dura-Tex), no reveal.

P/C 30483 (Elasto-Tex), no reveal.

Cedar Stake.

P/C 30621 (Dura-Tex), no reveal.

P/C 30924 (Elasto-Tex), no reveal.

Grooved Barnwood.

P/C 30704 (SPS), no reveal.

P/C 30450 (ABS), no reveal.

Rough-Sawn Plank.

P/C 30707 (SPS), no reveal.

P/C 30481 (ABS), no reveal.

10.

Extra Rough-Sawn.

P/C 30610 (Dura-Tex), no reveal.

P/C 30903 (Elasto-Tex), no reveal.

11.

1-1/2 Inch Variable Sawn.

P/C 30606 (Dura-Tex), reveal.

P/C 30485 (Elasto-Tex), reveal.

12.

Tongue and Groove.

P/C 30614 (Dura-Tex), no reveal.

P/C 30915 (Elasto-Tex), no reveal.

Ribbed Pattern Form Liners:

1/4 Inch Deep Rib.

P/C 30708 (SPS), reveal.

P/C 30472 (ABS), reveal.

1/2 Inch Deep Rib.

P/C 30709 (SPS), reveal.

P/C 30244 (ABS), reveal.

P/C 30663 (Dura-Tex), reveal.

P/C 30969 (Elasto-Tex), reveal.

3/4 Inch Deep Rib.

P/C 30710 (SPS), reveal.

P/C 30245 (ABS), reveal.

1 Inch Deep Rib.

P/C 30714 (SPS), no reveal.

P/C 30489 (ABS), no reveal.

1/2 Inch Deep Rib, 1-1/4 Inches OC.

P/C 30620 (Dura-Tex), no reveal.

P/C 30904 (Elasto-Tex), no reveal.

3/4 Inch Deep Rib, 2 Inches OC.

P/C 30727 (SPS), no reveal.

P/C 30460 (ABS), no reveal.

P/C 30661 (Dura-Tex), no reveal.

P/C 30968 (Elasto-Tex), no reveal.

3/16 Inch Long Ripple Rib.

P/C 30711 (SPS), no reveal.

P/C 30477 (ABS), no reveal.

3/16 Inch Short Ripple Rib.

P/C 30712 (SPS), no reveal.

P/C 30478 (ABS), no reveal.

Fractured Pattern Form Liners:

2 Inch Broken Rock Rib.

P/C 30719 (SPS), reveal.

P/C 30451 (ABS), reveal.

P/C 30619 (Dura-Tex), reveal.

P/C 30925 (Elasto-Tex), reveal.

Fine Stone Rib.

P/C 30716 (SPS), reveal.

P/C 30448 (ABS), reveal.

3/4 Inch Fractured Fin.

P/C 30717 (SPS), no reveal.

P/C 30449 (ABS), no reveal.

P/C 30604 (Dura-Tex), no reveal.

P/C 30906 (Elasto-Tex), no reveal.

3/4 Inch Narrow Fractured.

P/C 30603 (Dura-Tex), no reveal.

P/C 30909 (Elasto-Tex), no reveal.

3/4 Inch Fractured Fin.

P/C 30665 (Dura-Tex), no reveal.

P/C 30971 (Elasto-Tex), no reveal.

1 Inch Fractured Fin.

P/C 30720 (SPS), no reveal.

P/C 30492 (ABS), no reveal.

1-1/2 Inch Fractured Fin.

P/C 30666 (Dura-Tex), no reveal.

P/C 30972 (Elasto-Tex), no reveal.

1-3/4 Inch Fractured Fin.

P/C 30718 (SPS), no reveal.

P/C 30499 (ABS), no reveal.

P/C 30609 (Dura-Tex), no reveal.

P/C 30902 (Elasto-Tex), no reveal.

Fluted Fractured Fin.

P/C 30732 (SPS), no reveal.

P/C 30431 (ABS), no reveal.

P/C 30658 (Dura-Tex), no reveal.

P/C 30933 (Elasto-Tex), no reveal.

10.

Fractured Granite.

P/C 30611 (Dura-Tex), no reveal.

P/C 30907 (Elasto-Tex), no reveal.

11.

Stone Ground Granite.

P/C 30608 (Dura-Tex), no reveal.

P/C 30488 (Elasto-Tex), no reveal.

12.

Fractured Rope Rib.

P/C 30715 (SPS), no reveal.

P/C 30475 (ABS), no reveal.

P/C 30612 (Dura-Tex), no reveal.

P/C 30908 (Elasto-Tex), no reveal.

Broomed Pattern Form Liners:

Broom Swept.

P/C 30628 (Dura-Tex), no reveal.

P/C 30932 (Elasto-Tex), no reveal.

Stone Pattern Form Liners:

Phoenix Limestone.

P/C 30601 (Dura-Tex), no reveal.

P/C 30923 (Elasto-Tex), no reveal.

Round Stone.

P/C 30722 (SPS), no reveal.

P/C 30251 (ABS), no reveal.

P/C 30668 (Dura-Tex), no reveal.

P/C 30974 (Elasto-Tex), no reveal.

Small Crushed Stone.

P/C 30721 (SPS), no reveal.

P/C 30250 (ABS), no reveal.

Vertical Flagstone.

P/C 30607 (Dura-Tex), no reveal.

P/C 30486 (Elasto-Tex), no reveal.

Riverbed.

P/C 30626 (Dura-Tex), no reveal.

P/C 30930 (Elasto-Tex), no reveal.

Block Pattern Form Liners:

Masonry Slump Block.

P/C 30734 (SPS), no reveal.

P/C 30426 (ABS), no reveal.

P/C 30624 (Dura-Tex), no reveal.

P/C 30928 (Elasto-Tex), no reveal.

Ribbed Splitface Block.

P/C 30659 (Dura-Tex), no reveal.

P/C 30934 (Elasto-Tex), no reveal.

Brick Pattern Form Liners:

Rustic Brick.

P/C 30723 (SPS), no reveal.

P/C 30247 (ABS), no reveal.

P/C 30662 (Dura-Tex), no reveal.

P/C 30937 (Elasto-Tex), no reveal.

Striated Brick.

P/C 30724 (SPS), no reveal.

P/C 30222 (ABS), no reveal.

P/C 30660 (Dura-Tex), no reveal.

P/C 30935 (Elasto-Tex), no reveal.

Rusticated Pattern Form Liners:

Vertical Rustication.

P/C 30728 (SPS), no reveal.

P/C 30487 (ABS), no reveal.

P/C 30622 (Dura-Tex), no reveal.

P/C 30926 (Elasto-Tex), no reveal.

Striated Pattern Form Liners:

3/8 Inch Striated Random.

P/C 30726 (SPS), no reveal.

P/C 30493 (ABS), no reveal.

3/16 Inch Striated Random.

P/C 30725 (SPS), no reveal.

P/C 30248 (ABS), no reveal.

P/C 30602 (Dura-Tex), no reveal.

P/C 30967 (Elasto-Tex), no reveal.

Rolled Rib Pattern Form Liners:

P/C 30667 (Dura-Tex), no reveal.

P/C 30973 (Elasto-Tex), no reveal.

Sandblast Pattern Form Liners:

Sandblast No. 1 Fine.

P/C 30615 (Dura-Tex), no reveal.

P/C 30918 (Elasto-Tex), no reveal.

Sandblast No. 2 Medium.

P/C 30616 (Dura-Tex), no reveal.

P/C 30917 (Elasto-Tex), no reveal.

Sandblast No. 3 Coarse.

P/C 30617 (Dura-Tex), no reveal.

P/C 30918 (Elasto-Tex), no reveal.

Trowel Pattern Form Liners:

Skip Trowel Stucco.

P/C 30623 (Dura-Tex), no reveal.

P/C 30927 (Elasto-Tex), no reveal.

PART 3

EXECUTION

3.1

PREPARATION

** NOTE TO SPECIFIER ** Delete the following paragraphs if polyurethane form liners are not specified. Polyurethane form liners are slightly oil absorbent when new. It is recommended that an initial spray of form release be brushed in to help "season" and clean the pattern.

Work Liner Kote(tm) form release into all areas of form liner, especially pattern recesses.

Apply Liner Kote(tm) to form liners before each use and within the same day that concrete is placed.

Use form release sprayer and vary spray angle to ensure complete coverage of all pattern features.

Use a brush for deep or rough patterns.

** NOTE TO SPECIFIER ** Retain the paragraph below if repair of cuts or tears of polyurethane form liners will be allowed on the project.

Repair cuts or tears with Resi-Chem(R) P-1241 adhesive.

Work adhesive around edges of cut or tear and weight the area while adhesive is setting.

After setting, lightly sand residual adhesive to avoid gloss-producing spot in the concrete.

Repairs are subject to approval by the architect.

3.2

INSTALLATION

** NOTE TO SPECIFIER ** Architectural form liners can be attached to modular forming systems, job-built plywood forms, or precast beds. Select the procedure(s) for attaching form liners from the paragraphs below, deleting those not required.
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Concrete mix design (workability, pressure, color, set, and strength) will affect the use of form liners. Place concrete using a pump or conveyor with drop chute to avoid segregation. Place in two foot (610 mm) lifts and do not move material horizontally (uncontrolled horizontal movement may result in flow lines visible in the finished surface).

Attachment - Handset Systems; Plastic Form Liners:

Apply foam tape to plate or sill supporting formwork to prevent grout leakage at base of plastic form liner.

Assemble and brace the architectural side of the formwork first; attach form liner before setting ties or opposite formwork side.

Apply foam tape to back side of form liner along all edges; allow foam tape to extend beyond the edge when the form liner will be jointed.

Work with one sheet at a time; position form liner against formwork so that edges, pattern, and joints are square.

Staple form liner on 3 inch (76 mm) centers and around all tie locations; using adequate electrical power, drive staple heads flush with surface.

Position foam tape behind the joint of two pieces and press down firmly.

** NOTE TO SPECIFIER ** Delete the following subparagraph unless ribbed pattern is specified.

Insert grout seal block to support joint and prevent grout seepage.

Insert grout seal blocks as required to seal tie holes, fill voids in boxouts and open-ended patterns, or support especially deep patterns.

Attachment - Gangform Systems; Plastic Form Liners:

Level and square formwork so that attachment can be made in a horizontal plane; mark dimensions so that edges, patterns, and joints are square.

If required, attach strongbacks to the formwork holding the form liner.

Apply foam tape to plate or sill supporting formwork to prevent grout leakage at base of plastic form liner.

Apply foam tape to back side of form liner along all edges; allow foam tape to extend beyond the edge when the form liner will be jointed.

Work with one sheet at a time; position form liner against formwork so that edges, pattern, and joints are square.

Staple form liner on 3 inch (76 mm) centers and around all tie locations; using adequate electrical power, drive staple heads flush with surface.

Position foam tape behind the joint of two pieces and press down firmly; make attachment.

Insert grout seal blocks as required to seal tie holes, fill voids in boxouts and open-ended patterns, or support especially deep patterns.

Attachment - Handset Systems; Polyurethane Form Liners:

Assemble and brace the architectural side of the formwork first; attach form liner before setting ties or opposite formwork side.

Work with one sheet at a time; position form liner against formwork so that edges, pattern, and joints are square.

Attach form liner with box nails (or staples) at approximately 6 inches (152 mm) on center.

Attach top edge and one side of form liner to formwork; check overall dimensions and position.

Complete the attachment using box nails (or staples) at approximately 12 inches (305 mm) on center in both directions throughout the field of the form liner and at 6 inches (152 mm) on center along the perimeters.

Apply compressible adhesive-backed foam tape to form liner edges; firmly butt edges. Compress joints as tightly as possible without buckling or distorting the pattern.

Dress joints and edges with a power rotary rasp or sander to match pattern features as closely as possible.

Attachment - Gangform Systems; Polyurethane Form Liners:

Level and square formwork so that attachment can be made in a horizontal plane; mark dimensions so that edges, patterns, and joints are square.

** NOTE TO SPECIFIER ** Caution: Adhesives will not provide adequate attachment if formwork contains residual form release.

Roughen formwork face and back side of form liners to accept adhesive; clean dust and debris from both surfaces with solvent.

Snap lines on form for positioning.

Position form liner and roll back more than half onto itself; work with one sheet at a time.

Prepare adhesive according to manufacturer's instructions; spread uniformly on formwork face and back of form liner, checking edges and corners to ensure application to these areas.

When adhesive is tacky, slowly roll form liner back onto formwork face, eliminating air pockets between surfaces.

Position edges and corners, securing with wood tack strips for dimensional stability.

Roll back other half and apply adhesive to formwork face and back of form liner, checking edges, corners, and center adhesive line to ensure application to these areas.

When adhesive is tacky, slowly roll form liner back onto formwork face, eliminating air pockets between surfaces.

10.

Position edges and corners, securing with wood tack strips for dimensional stability.

11.

Allow 48 hours for complete setting.

** NOTE TO SPECIFIER ** Delete the following subparagraph if joints are not required.

12.

Apply adhesive to form liner edges and butt edges firmly; compress joints as tightly as possible without buckling or distorting pattern.

13.

Evenly weight down form liner to assure consistent adhesion to formwork face.

14.

Dress joints and edges with a utility knife or sander to match pattern features as closely as possible.

Attachment - Plywood; Polyurethane Form Liners:

** NOTE TO SPECIFIER ** If a secondary underlayment is attached to forms, and form liner attached to it, 1/2 inch (12.7 mm) or 3/4 inch (19.1 mm) unoiled plywood should be used. If the form face is not sacrificial, the best method of attachment is with minimum 1/4 inch (6.3 mm) Tee Nuts placed at 1 foot (305 mm) on center for 1/2 inch (12.7 mm) plywood, 2 feet (610 mm) on center for 3/4 inch (19.1 mm) plywood. A washer is required on the back side of a plywood face sheet form.

Roughen formwork face and back side of form liners to accept adhesive; clean dust and debris from both surfaces with solvent.

** NOTE TO SPECIFIER ** Caution: Adhesives will not provide adequate attachment if formwork contains residual form release.

Allow form liner to overhang edges 1/32 inch (0.8 mm) when joints are required on the gang.

Position form liner and roll back more than half onto itself; work with one sheet at a time.

Prepare adhesive according to manufacturer's instructions; spread uniformly on formwork face and back of form liner, checking edges and corners to ensure application to these areas.

When adhesive is tacky, slowly roll form liner back onto formwork face, eliminating air pockets between surfaces.

Position edges and corners, securing with wood tack strips for dimensional stability.

Roll back other half and apply adhesive to formwork face and back of form liner, checking edges, corners, and center adhesive line to ensure application to these areas.

When adhesive is tacky, slowly roll form liner back onto plywood face.

Position edges and corners, securing with tack strips for dimensional stability.

10.

Allow 48 hours for complete setting.

** NOTE TO SPECIFIER ** The plywood with form liner attached is ready for mounting to formwork following the steps above.

11.

Mark dimensions so that edges, patterns, and joints are square when mounting.

12.

Attach plywood with form liner to gangform; drive screws into plywood from back of form face at 12 inch (305 mm) centers, capturing 3/4 of plywood thickness.

13.

Once mounted, dress joints and edges with a utility knife or sander to match pattern features as closely as possible.

** NOTE TO SPECIFIER ** Polyurethane form liners can be attached to plywood at the factory according to customer specifications. The process is similar to the plywood attachment specified above. A choice of bolts, strapping, or banding is available for subsequent mounting to formwork.

END OF SECTION