ONE: FORMING AND MIXING

• This form is open on one side, unlike a traditional concrete form that would need to be capped.
• The fiber-reinforced concrete mix can be sprayed in the form and hand-packed to the full 1″ thickness.
• The fiber-reinforced concrete mix can be sprayed in the form and hand-packed to the full 1″ thickness.
• The tall wall on the left in these pictures is removed when the piece needs to be demolded.
• Every time the form is re-assembled, it needs to be caulked to make it water-tight.

• The casting surface is made from 3/4″ melamine-coated particle board.
• The rest of the form is made from 3/4″ plywood, braced with 2×4’s, and assembled with drywall screws.

• After the form is assembled and sealed, clean it up with denatured alcohol.
• Placing the forms on saw horses will elevate it and make spraying easier.
• The form can be rotated or flipped depending on what surface is being sprayed or hand-packed.

• Add one gallon of Diluted Activator or Pre-Cast Modifier per 50-lb. bag.
• Then add any Smart Color Pigment or Surecrete Color Packs and blend thoroughly.

Step 5 – Add Concrete Mix

• Add 1/2 bag of D-FRC or PreCast Mix.
• Blend thoroughly, being sure to rotate the bucket, scrape down the sides, and make sure any unmixed material at the bottom is blended in.
• Add the remaining 1/2 of the bagged mix and continue blending.

Step 6 – Scrape the Sides

• Scrape down the sides and bottom of the bucket with a trowel.
• Mix again until there is no unmixed material.

Step 7 – Check the Consistency of the Mix

• 16 ounces of additional water can be added to the mix.
• Use a wet mix if the material is going to be sprayed or cast.
• Use a firmer mix if it is going to be hand-packed.