How To Pre Cast Concrete Walls Created to Rebuild New Orleans

Inside working space was limited but accomodated the EZ Mix Meter Mix machine and drum units of VytaFlex 60.

The original model over which liquid mold rubber will be is poured is constructed out of a combination of wood and polyester resin. All decorative details are perfected at this point so they are reproduced each and every time they are cast with concrete. Mold (form) boards are then fastened to the outside of the model and then seams are caulked to prevent rubber from leaking.

Because the original model is made mostly from porous wood, it is necessary to apply a sealing agent. In this case, Smooth-On’s Sonite Wax II® is used because it not only seals the porosity on the original model, but does so in a way that does not effect the detail.

In addition to the sealing agent, a release agent is required to facilitate the easy demold of the Vytaflex® 60 rubber from all surfaces. Smooth-On’s Universal Mold Release is applied to all surfaces using the Kwikee® Sprayer.

To cut down on the amount of rubber used, ''blockouts'' are incorporated at strategic points along the mold structure. 1'' pieces of plywood are used to make the blockouts, which are fastened to the formboards with screws so they do not float in the liquid rubber.