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	SECTION 03121
	FORMLINERS FOR ARCHITECTURAL CONCRETE
	** NOTE TO SPECIFIER ** Architectural Polymers, form liners, brick inlay. Concrete art and concrete stains . This section is based on the products of Architectural Polymers, which is located at: 1220 Little Gap Rd. Palmerton, PA 18071 Tel: (610) 824-3322 Fax: (610) 824-3777 Email: Web: www.architecturalpolymers.com [ Click Here ] for additional information. For 15 years, Architectural Polymers has been recognized in the concrete form fabrication industry as a leader in launching a vast array of innovative methods to benefit the architectural community. From reliably producing a high quality form liner concrete mold to adorn theme environments of concrete art on North America's Highways, or custom manufacturing thin brick inlay systems to clad schools, hospitals, commercial office buildings, condominiums, or parking decks with real thin brick, we know attention to detail is essential. We thrive on finding cost effective solutions resulting in a beautiful decorative concrete structures. By way of continued integrity and excellence, we now supply architects, owners, general contractors, and pre-cast concrete manufacturers with the top three choices of quality thin brick. Respected thin brick manufacturers such as Summitville Tile, Endicott Clay, and Metrobrick have all enthusiastically given Architectural Polymers the thumbs up' to offer their product line with the Versa-brix® Family or the Tabs II Wall System. As a system of thin brick, single and multi-use thin brick form liner, service and accessories, this marriage supplied in its entirety reduces the cost to the consumer. Custom possibilities of architectural concrete art and standard form liner textures are our expertise and can be manufactured in lightning speed. Mold rubber for in-house-made form liner, concrete form oils, form liner glue and other casting resin products are just a mouse click away on our on-line store. Free shipping for large orders of liquid rubber have made the craft hobby and architectural product enthusiast a frequent visitor to our easy-to-navigate site. After moving into our new state-of-the-art manufacturing facility in the summer of 2005, equipment upgrades have exponentially increased our potential to provide you with additional unparalleled product lines at the same speed and quality. Architects can attend our seminars for continued education credits in decorative concrete or inquire about a sales representative stopping by for a personalized visit. You may also download our Versa-brix® video for an online demonstration in Thin Brick Inlay Systems. .
	PART 1	GENERAL
	1.1	SECTION INCLUDES
	** NOTE TO SPECIFIER ** This section covers more than 60 standard form liner textures in four different form liner materials. Material can also be supplied to meet custom specifications upon request. Delete items below not required for project.
		A.	Plastic form liners for concrete.
		B.	Polyurethane form liners for concrete.
	1.2	RELATED SECTIONS
	** NOTE TO SPECIFIER ** Delete any sections below not relevant to this project; add others as required.
		A.	Section 03100 - Concrete Formwork.
		B.	Section 03120 - Architectural Cast-In-Place Concrete Formwork.
		C.	Section 03330 - Architectural Concrete.
		D.	Section 03350 - Concrete Finishes.
		E.	Section 03400 - Precast Concrete.
		F.	Section 03450 - Architectural Precast Concrete - Plant Cast.
		G.	Section 03460 - Architectural Precast Concrete - Site Cast.
		H.	Section 03470 - Tilt-Up Concrete.
	1.3	REFERENCES
	** NOTE TO SPECIFIER ** Delete references from the list below that are not actually required by the text of the edited section.
		A.	American Concrete Institute (ACI):
			1.	ACI 117 - Standard Tolerances for Concrete Construction and Materials.
			2.	ACI 301 - CH. 13, Specifications for Structural Concrete.
			3.	ACI 303R-91 - Guide to Cast-in-Place Architectural Concrete.
			4.	ACI 309 72 [78] - CH. 7, Recommended Practice for Consolidation of Concrete.
			5.	ACI 347 78 - CH. 5.2, Recommended Practice for Concrete Formwork.
	1.4	SUBMITTALS
		A.	Submit under provisions of Section 01300.
		B.	Product Data: Manufacturer's data sheets on each product to be used, including:
			1.	Preparation instructions and recommendations.
			2.	Storage and handling requirements and recommendations.
			3.	Installation methods.
	** NOTE TO SPECIFIER ** Delete selection samples if colors have already been selected.
		C.	Selection Samples: For each finish product specified, two complete sets of color chips representing manufacturer's full range of available colors and patterns.
		D.	Verification Samples: For each finish product specified, two samples, minimum size 24 inches (610 mm) square, representing actual product, color, and patterns.
	1.5	QUALITY ASSURANCE
		A.	Manufacturer Qualifications: Company manufacturing form liners continuously for 15 years.
		B.	Installer Qualifications:
		C.	Architect/Engineer's review for aesthetic criteria. Contractor responsible for design of formwork and back-up of form liner for structural stability and sufficiency.
	** NOTE TO SPECIFIER ** Include a mock-up if the project size and/or quality warrant taking such a precaution. The following is one example of how a mock-up on a large project might be specified. When deciding on the extent of the mock-up, consider all the major different types of work on the project.
		D.	Mock-Up: Provide a mock-up for evaluation of surface preparation techniques and application workmanship.
			1.	Provide full scale mock-up using contract materials, methods and workmanship. Incorporate formwork accessories and minimum one vertical and one horizontal form liner joint. Include concrete mix, forming system, form release agents, placement rate, form pressures, joint sealing, vibrating and stripping practices. Demonstrate patching and repair procedures for spawled concrete, and voids caused by honeycombing or bug holes.
			2.	Approved mock-up shall be the standard by which Work will be evaluated.
	1.6	DELIVERY, STORAGE, AND HANDLING
		A.	Inspect the materials upon delivery to assure that specified products have been received.
		B.	Store liners in closed shipping crates until needed in work site; protect from sunlight, dirt, and debris.
		C.	Once attached to framework, store liners on edge. Avoid striking face with heavy, sharp, or heated objects that could cause permanent damage.
		D.	Store and dispose of solvent-based materials, and materials used with solvent-based materials, in accordance with requirements of local authorities having jurisdiction.
	1.7	PROJECT CONDITIONS
		A.	Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer's absolute limits.
	PART 2	PRODUCTS
	2.1	MANUFACTURERS
		A.	Acceptable Manufacturer: Architectural Polymers, which is located at: 1220 Little Gap Rd. ; Palmerton, PA 18071; Tel: 610-824-3322; Fax: 610-824-3777; Email: request info; Web: www.architecturalpolymers.com
	** NOTE TO SPECIFIER ** Delete one of the following two paragraphs; coordinate with requirements of Division 1 section on product options and substitutions.
		B.	Substitutions: Not permitted.
		C.	Requests for substitutions will be considered in accordance with provisions of Section 01600.
	2.2	MATERIALS
	** NOTE TO SPECIFIER ** Generally, AP Elastomeric 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; Elastomeric form liners allow up to 100 reuses. In all cases, reuse is subject to pattern configuration, proper handling, and job site conditions.
		A.	Form Liner Material: AP Elastomeric: Premium polyurethane elastomer or elastomer with foam core.
		B.	Form Release: AP release 2550.
	** NOTE TO SPECIFIER ** Retain subparagraphs below as required for the project. Consult manufacturer for types and brand names of required materials.
		C.	Silicone Caulking: As recommended by form liner manufacturer.
		D.	Adhesive: As recommended by form liner manufacturer.
		E.	Solvent: As recommended by form liner manufacturer.
	** 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.
		F.	Staples: 9/16 inch (14 mm) or 3/4 inch (19 mm), depending on pattern thickness.
		G.	Screws, nails or other fasteners: As recommended by form liner manufacturer.
	2.3	PRODUCTS
	** NOTE TO SPECIFIER ** Select standard product(s) and pattern(s) and note by pattern name and product code. Delete liner types and patterns not required.
		A.	Stone and Block Textures:
			1.	14-3/4 inches Horseheads Quarry Stone - #890.
			2.	Riverstone - #891.
			3.	12 inches Quarry Stone - #892.
			4.	14 inches Quarry Stone - #893.
			5.	16 inches Quarry Stone - #894.
			6.	21 inches Quarry Stone - #895.
			7.	24 inches Quarry Stone - #896.
			8.	15 inches Rustic Granite - #897.
			9.	Rustic Ashlar Stone - #898.
			10.	Northeast River Stone - #899.
			11.	2 x 8 Split Block - #900.
			12.	8 x 16 Split Block - #901.
			13.	9 x 18 Split Block with Deep Mortar - #902.
			14.	8 x 8 Split Block - #903.
			15.	Ashlar Stone - #904.
			16.	Small Aged Ashlar Stone - #905.
			17.	Ashlar Stone Heavy Cut - #906.
			18.	Coral Ashlar Stone - #907.
			19.	BQE Old Cut Ashlar Stone - #908.
			20.	West Moreland Drystack - #909.
			21.	Median Barrier Drystack - #910.
			22.	Large Stone Drystack - #911.
			23.	Valley Forge Fieldstone - #912.
			24.	New York DOT Ashlar - #913.
			25.	New York DOT Ashlar - #913A.
			26.	New York DOT Ashlar - #913B.
			27.	Small Aged Ashlar w/ modified thin joints - #914.
			28.	Small Rustic Ashlar - #916.
			29.	8x8 Split Block Running Bond - #917.
			30.	12x24 Split Limestone Running Bond - #918.
			31.	Split Slate - #921.
			32.	Cleaved Limestone - #922.
	** NOTE TO SPECIFIER ** Brick textures are an ideal for bridges, sound barrier and retaining walls. With just about any brick size, style, and era available: brick textures are an excellent choice for textured concrete as a complement to already existing brick structures. Colorized brick textures are simple and cost effective, and offer longevity. AP Brick textures may also be utilized as an alternative to thin brick cladding. Delete liner not required.
		B.	Brick Textures:
			1.	Standard Brick (coved) - #101A.
			2.	Standard Brick (raked) - #101B.
			3.	Utility Brick Wirecut - #1021/3 Running Bond Utility - #103.
			4.	18th Century Brick - #104.
			5.	Smooth Utility Brick (coved) - #105A.
			6.	Smooth Utility Brick (raked) - #105B.
			7.	Standard Brick Smooth (coved) - #107A.
			8.	Standard Brick Smooth (raked) - #107B.
			9.	Standard Brick Sand Finish - #108.
	** NOTE TO SPECIFIER ** AP's wood textures are excellent choices for sound barrier, retaining walls, and the med concrete construction. It is often found in situations where concrete structures are needed in a very rural and wooded setting. Delete liners not required.
		C.	Wood Textures:
			1.	Barn Boards - #501.
			2.	5 inches and 3 inches Cedar - #502.
			3.	Cedar Stakes - #503.
			4.	6 inches Shiplap - #504.
			5.	Exaggerated Stakes - #505.
			6.	Staggered Oak - #506.
			7.	Staggered Oak Heavy - #507.
			8.	1 inch Split Cedar Stakes - #508.
			9.	5 inches Weathered Wood - #509.
	** NOTE TO SPECIFIER ** Flat textures are often cleverly combined for use in concrete art. Slight contrasts between two or three flat textures can have a powerful effect while viewing from distances beyond 50 ft. AP's flat textures such as light sandblast and worm stucco are often found on commercial offices, parking decks, and warehouses. Delete liner not required.
		D.	Flat Textures:
			1.	Exposed Aggregate - #401.
			2.	Popcorn - #402.
			3.	Light Sand Finish - #403.
			4.	Medium Sand Finish - #404.
			5.	Smooth Finish - #405.
			6.	Worm Stucco - #406.
			7.	Broom - #407.
			8.	Brush Hammered - #408.
	** NOTE TO SPECIFIER ** Ribbed textures are often used to break up an area of smooth and uninteresting concrete. While mainly found running vertically, ribbed patterns can be used in any manner, including concrete art scenes. Delete liners not required.
		E.	Rythmic Textures:
			1.	1/2 inch Sinewave - #301.
			2.	3/4 inch Fin - #302.
			3.	3 inches Fin - #303.
			4.	Wyeth Aherst Rib - #304.
			5.	3/8 inch Smooth Flute 1 O.C. - #305.
			6.	1-1/2 inches Deep Smooth Rib - #306.
			7.	1-3/4 inches Smooth Flute 2 1/4 inches O.C. - #307.
			8.	2 inches Deep Smooth Flute 2 inches O.C. - #308.
			9.	1 inch Light Textured Flute 2 inches O.C. - #309.
			10.	Pyramid Flute 8 inches O.C. - #310.
			11.	Deep Smooth Rib - #311.
	** NOTE TO SPECIFIER ** Fractured textures are often found on highways, retaining walls, parking decks and commercial office structures. There are many different varying patterns offering a unique look suited to any landscaping idea. Fractured textures are often used in concrete art scenes. Delete liner not required.
		F.	Fractured Textures:
			1.	M & R Modified - #201.
			2.	Tree Bark - #202.
			3.	1 inch Standard Fractured Fin - #203.
			4.	1.5 inches Architectural Rib - #204.
			5.	Flat Fractured Rib - #205.
			6.	3/4 inch Standard Fractured Fin - #206.
			7.	1 inch Fractured Rope - #207.
			8.	Wavy Carolina Fractured Rib - #208.
			9.	1/2 inch Fractured Fin - #209.
			10.	NY Fractured Fin - #210.
			11.	Sound Absorptive Broken One Foot Ribs - #211.
	** NOTE TO SPECIFIER ** Polyurethane form liners can be attached to plywood at the factory according to customer specifications. The process is similar to the in the field plywood attachment specified. A choice of bolts, strapping, or banding is available for subsequent mounting to framework. Provide contract provisions or delete if not required.
	2.4	FACTORY FABRICATION
		A.	Provide custom work as indicated to achieve casting of Concrete Art, Custom patterns, etc.)
		B.	Polyurethane form liners shall be attached to plywood at the factory according to customer specifications. The process is similar to the in the field plywood attachment specified. A choice of bolts, strapping, or banding is available for subsequent mounting to framework.
	PART 3	EXECUTION
	3.1	EXAMINATION
		A.	Do not begin installation until substrates have been properly prepared.
		B.	If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.
	3.2	PREPARATION
		A.	Prepare surfaces using the methods recommended by the manufacturer for achieving the best result for the desired affect under the project conditions.
	** 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.
		B.	Work neutral-type AP release 2550 into all areas of form liner, especially pattern recesses.
	** NOTE TO SPECIFIER ** Delete the paragraph above and retain the paragraph below if super plasticizers or micro silica are specified for the concrete. Retain the paragraph below for all polyurethane form liners.
		C.	Apply AP Release 2550 to form liners before each use and within the same day that concrete is placed.
			1.	Use form release sprayer and vary spray angle to ensure complete coverage of all pattern features.
			2.	Use multiple coats for complete coverage on 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 project.
		D.	Where acceptable to Architect, repair cuts or tears with AP Gel 80 adhesive.
			1.	Work adhesive around edges of cut or tear and weight the area while adhesive is setting.
			2.	After setting, lightly sand residual adhesive to avoid gloss-producing spot in the concrete.
			3.	Repairs are subject to approval by the architect.
	3.3	INSTALLATION
		A.	Install in accordance with manufacturer's instructions.
	** 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. Concrete mix design (workability, pressure, color, set, and strength) will affect the use of the form liners. Place concrete using a pump or conveyor with drop cute to avoid segregation. Place in 2 feet (610 mm) lifts and do not move material horizontally (horizontal movement may result in visible flow lines in the surface).
		B.	Attachment - Handset Systems; Polyurethane Form Liners:
			1.	Assemble and brace the architectural side of the formwork first; attach form liner before setting ties or opposite formwork side.
			2.	Work with one sheet at a time; position form liner against formwork so that edges, pattern and joints are square.
				a.	Attach form liner with box nails (or staples) at approximately 6 inches (152 mm) on center.
				b.	Attach top edge and one side of form liner to formwork; check overall dimension and position.
				c.	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 perimeters.
			3.	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.
			4.	Dress joints and edges with a power rotary rasp or sander to match pattern features as closely as possible.
		C.	Attachment - Gangform Systems; Polyurethane Form Liners:
			1.	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 ** Adhesives will not provide adequate attachment if formwork contains residual form release or dust.
			2.	Roughen formwork face and back side of form liners to accept adhesive; clean dust and debris from both surfaces with solvent.
			3.	Snap lines on form for positioning.
			4.	Position form liner and roll back on it; work with one sheet at a time.
			5.	Prepare adhesive according to manufacturer's instructions; spread uniformly on formwork and back of form liner, checking edges and corners to ensure application to these areas.
			6.	When adhesive is tacky slowly roll form liner back onto formwork face, eliminating air pockets between surfaces.
			7.	Position edges and corners, securing with wood tack strips for dimensional stability.
			8.	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.
			9.	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.
		D.	Attachment - Plywood; Polyurethane Form Liners:
	** NOTE TO SPECIFIER ** If a second underlayment is attached to forms, and form liner attached to it, un-oiled 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 or Magnets.
			1.	Roughen formwork face and back side of form liners to accept adhesive; clean dust and debris from both surfaces with solvent.
	** NOTE TO SPECIFIER ** Adhesives will not provide adequate attachment if formwork contains residual form release.
			2.	Allow form liner to overhang edges 1/16 inch (0.8 mm) when joints are required on the gang.
			3.	Position form liner and roll back more than half onto itself; work with one sheet at a time.
			4.	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.
			5.	When adhesive is tacky, slowly roll form liner back onto formwork face, eliminating air pockets between surfaces.
			6.	Position edges and corners, securing with wood tack strips for dimensional stability.
			7.	Roll back other half and apply adhesive to formwork face and back of form liner, checking edges and corners, and center adhesive line to ensure application to these areas.
			8.	When adhesive is tacky, slowly roll form liner back onto plywood face.
			9.	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 gang form; drive screws into plywood from back of form face at 12 inches (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.
	3.4	CONCRETE PLACEMENT
		A.	Schedule concrete placement and lifts not to exceed form pressures of 1000 psf (48 MPa).
		B.	Thoroughly vibrate concrete to achieve consolidation, and minimize voids. Internally vibrate into previous lift to avoid lift lines. Avoid vibrator contact with the form liner.
	3.5	PROTECTION
		A.	Protect installed products until completion of project.
		B.	Touch-up, repair or replace damaged products before Substantial Completion.
	END OF SECTION