CONCRETE FORMWORK

I came to Architectural Cast Stone (ACS) as the head of the CAD / CAM department to modernize their formbuilding workflow.

The concrete industry has been slow to adopt new technologies. Despite being one of the leading providers of architectural furnishings in the midwest and northeastern United States, prior to my arrival, ACS created all their formwork using traditional materials and processes, in use for virtually the entire 20th century. Frankly, I was astounded at the complexity of their output before I got here, but I quickly came to appreciate the true craftsmanship displayed by their highly experienced workforce. Many of them were worried that I was going to replace them.

Instead, my department has dovetailed seamlessly into the production workflow.

Our forms are still made from a range of traditional materials: wood, fiberglass, and rubber, but EPS foam has replaced many of the most tedious and time consuming processes. (We use WAY less Bondo now.)

Probably about 50% of our production is now entirely EPS foam, the other 50% being hybrid mixes of whichever materials make sense given the application.

The CNC mill and wirecutters are used for negative form production but also positive master machining and jig-making, cutting not just foam, but plywood and PVC and polyurea and MDF.

My CAD modeling abilities have also contributed to a streamlining of form production, even for traditional wood forms. I can often find ways to make a single form work for several variations of a part where previously separate forms would have been required.

ACS is now actively pursuing the “tough” jobs - the ones with complex, flowing geometry, where our competition simply can’t compete with our efficiency and experience.

Click to see my vision for 3D concrete printing.

See below for some examples of my form work.