For creating concrete counter tops with a decorative cantilever edges, Pacific Formliner offers its counter top series of profiles, specially dimensioned for use with 1 ½ or 2” thick concrete. These profiles create a standard 1 ½” cantilever from the face of the cabinet. Use painters masking tape, double sided tape (DT-D2) and twist to break wire kits for installation on prefinished cabinets. Start by establishing the finish height of the concrete and verify that the cabinet is securely in place and level.
Setting Pacific Formliner
It is always best to set and place the formliner the day of the pour. All Pacific Formliner profiles come 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 finished height of the concrete or the ½” lip can be incorporated into profile design and the concrete can be poured flush. On prefinished cabinets a layer of painters masking tape should be applied to protect the cabinet finish from contact with the double sided tape. When using the double sided tape all surfaces must be dust free and dry. Starting at one end, apply the double sided tape either to the lower portion of the formliner or the cabinet surface, then remove the tape liner a foot or two at a time and firmly stick the pacific formliner to the cabinet, maintaining the proper elevation as you go. Using a saw or knife, miter cut your corners as necessary.
Apply a moisture barrier to the top of the cabinet if necessary, then install concrete nails or screws into the top of the cabinet at 12 to 18 inches on center approximately 6 to 8 inches back from the face, leaving the head exposed enough to tie the twist to break wire around. Align the twist to break wire with the concrete nail or screw perpendicularly, slide a fender washer onto the twist to break wire and push the twist to break wire thru the form, wrap and secure the wire to the exposed head of the nail or screw. Loosen or tighten the twist to break wires as necessary to maintain the desired form alignment.
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 cantilever edges. After the concrete has sufficiently set up and will hold its shape begin removal of the formliner. Start by twisting the exposed wire heads in one direction, after a few turns the wire will snap, now remove the wire by pulling it straight out and discard.
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.