For creating decorative concrete steps with Pacific Formliner layout and set-up the formwork as you would normally using 2 x 8s, 2 x 6s, 1x 6s, bender board, plywood or similar materials. A standard step rise of 6” or 7-1/2” is achieved with standard sized Pacific Formliner. Layout your rise and run accordingly. For special rise and height requirements Pacific Formliner can be easily cut to size using a saw or it can be special ordered from the factory to meet your size requirements.
Setting Pacific Formliner
It is always best to set and place the formliner the day of the pour. All Pacific Formliner profiles comes with a ½” lip at the top to prevent tattering and increase its usable life. Consequently Pacific Formliner needs to be installed ½” above the formwork (finished surface), a small ½” spacer block will help facilitate this alignment or use a tape measure. Cut Pacific Formliner to length, using a saw or knife, to snuggly fit inside your formwork, miter cut your corners as necessary. Now align and secure the formliner in place using spray glue, double sided tape or 3” finish nails. The 3” finish nails being the preferred method, are placed approximately 12 to 18 inches on center with a minimum of 2 nails per piece. The nails should be placed perpendicular to the face of the formliner just below the profile and driven thru the formliner into the wooden formwork, set the nail flush or just below the surface of the formliner.
Apply a suitable non petroleum based form release, such as vegetable oil or soapy water, to the formliner prior to placing the concrete. Slow and careful concrete placement will help reduce voiding, blowout and misalignment of forms. As with any concrete job careful attention to the form alignment after the concrete is poured should be a priority as any form adjustments or re-alignments must be done while the concrete is in its initial plastic state. The use of mechanical internal or external vibration is recommended to properly consolidate the concrete and thus reduce voids and air pockets.
Concrete mix design: Always use a properly proportioned concrete mix with a low water/cement ratio that will achieve a minimum of 2500 psi or greater compressive strength @ 28 days
Stripping and finishing should be done in progressive stages just as you would when finishing normal concrete steps. With the use of finish nails you can easily remove the wooden formwork while leaving the formliner in place. Use a margin trowel or similar to hold the formliner in place while the formwork is removed. After the concrete has sufficiently set up and will hold its shape begin removal of the formliner.
Proper caution and care is needed when removing/stripping the formliner, start at one end and gently roll and peel the formliner away, avoid any vertical movement. Immediately begin the floating and finishing process to create the desired concrete finish.
Clean up and Storage Rinse and clean the formliner with water and a scrub brush after each use. Pacific Formliner should be stored flat, out of direct sunlight in a dry protected environment. Proper cleaning and storage will prolong the life and usage of Pacific Formliner.