To see the concrete result, ask for our pouring sample pack or view the photos at the bottom:
These samples give an idea of what the possibilities are in relation to material and finish for concrete design elements. You can use it to perform tests with your specific concrete mix.
The reaction of the raw materials from a concrete mix or a processing method may, after all , mean that a reaction may occur that means that the concrete will discolour, gets a smoother or rougher texture or that deposits occur (that may or may not be temperature sensitive) of the material of the concrete design element.
The shape of the concrete product, however, also determines what the possibilities are that can be considered. When you use these samples, support formwork is always required.
(for example: EPS 100 also known as “P20”) This is bare expanded polystyrene with a density of 20 kg per m³ and a compressive strength of 100 kPa at 10% deformation (this matches 1 kg per cm²). Expanded polystyrene can also be produced in other densities: EPS 60 (15 kg/m³), EPS 150 (25 kg/m³) EPS 200 (30 kg/m³), EPS 250 (35 kg/m³) and EPS 300 (40 kg/m³). Pieces larger than 4000 x 1200 x 1000 are glued together. The seams will remain visible in the concrete. The concrete look can be compared with rough sanding paper.
If the delineation of the granulate must be finer, select a higher density.
This is polyurethane with a density of 40 kg per m³. Pieces larger than 2500 x 1250 x 740 are glued together using PU adhesive. The seams will remain visible in the concrete.
The concrete look can be compared to a sand structure.
EPS clad with orange PVC foil
Due to the orange foil, there is less adhesion of the concrete onto the template and this makes releasing easier. The foil has a maximum width of 1200 mm. If the dimensions of the design element are greater than 1200 mm, the orange foil is used with an overlap. This, however, will leave an imprint in the concrete. The foil can be used in relation to single curved surfaces but not double curved surfaces (such as a sphere). The concrete look can be compared to an orange peel.
EPS clad with impact-resistant polystyrene film
Due to the 1 mm thick impact resistant film, there is less adhesion of the concrete onto the template. This film also consists of a 2 mm thick version. A design element larger than 2100 on 1000 mm can no longer be clad in one piece of 1 mm impact-resistant film and then there will be an overlap. The 1 mm impact resistant film can only be used on curved surfaces but not on double curved surfaces (such as a sphere). The 2 mm impact resistant film cannot be used on curved surfaces. The concrete look will be relatively smooth.
EPS clad with wax
EPS clad with wax
The cladding with wax is used to make the removal of the concrete easier. The side cladded with wax feels greasy and has a yellow sheen. The wax can only be applied on curved and double curved surfaces. Residue of the wax will remain on the concrete and therefore the concrete becomes greasy.
The concrete look can be compared with fine sanding paper.
Independently from the material and cladding, due care must always be taken when handling the design elements. Throwing, exerting pressure or walking over the design elements results in damage (including in relation to cladding using impact-resistant film). A concentrated load (such as of reinforcing steel and spacers) always leads to indentation and therefore a bump will occur on the concrete.
Concrete may discolour due to a reaction from a concrete mix or a finishing method. The concrete can also get a smoother or rougher texture.