Application Guide Line

for RECKLI-Formliners

Table of
Contents

1. Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. Delivery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7. Heat Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8. Pattern Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
9. Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10. Application for Pre-cast Concrete Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
11. Application for In-situ Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12. Adhering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13. Release Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14. Spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
15. Concrete Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
16. Striking/Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
17. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
18. Joints/Corners/Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
19. Stop-offs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
20. Repairing of Formliners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
21. Waste Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
22. Consumption and Requirement Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1. Classification

4. Delivery Check

6. Transport

We distinguish our formliners with the prefix

numbers 1/.. and 2/.. The most important
distinguishing features are listed in table 1.
There is also available another type of formliner with the prefix number 3/.. These formliners are for one use only. This working
guide applies only to the formliners with the
pre fix1/.. and 2/.. For the OneTimer
Formliners prefix number 3/.. there is a
separate catalogue with the relevant guide.

Upon delivery please check your consignment immediately for any damage sustained in transport. If you note any damage to
your consignment you must describe it in
detail on the delivery note and get the driver
to countersign your comments. Before
using the formliners first check the required
dimensions as detailed on the package
especially to the longitudinal direction (ld)
of the pattern if there is one.

6.1 Boxes and pallets

The boxes and pallets with the formliners
1/.. can usually be transported and moved
by fork-lift or crane. The pallets with the
formliner rolls can also be transported and
moved by fork-lifts or cranes.

2. Material

5. Storage

The formliners consist of rubber-like

Polyurethane Elastomers. The high flexibility
and elasticity allow a damage-free release
of the concrete and exact reproduction of
the pattern and allowing for undercuts and
shallow grooves.

Before fixing all formliners must be stored

dry and level to avoid deformation of the
pattern. If using the 2/.. formliners loosely
(not adhered) they can be rolled up tightly
again onto the cardboard rolls after use.
Make sure the formliners rolls do not have
any heavy or sharp objects stored on top of
them as this would lead to permanent
deformation.
The formliners must be protected against
intensive weathering such as UV light, rain,
frost and any other aggressive conditions.
This is best accomplished by covering with
dark or black polyethylene or other waterproof sheets. (Picture 2)

3. Delivery
For the formliners with the index 1/.. we
deliver them flat on pallets or in chipboard
boxes.
The formliners 2/.. are rolled up on heavy
duty cardboard rolls for transport and storage and wrapped in heavy brown kraft
paper and/or polyethylene for extra protection against dirt. Depending on the size and
weight they are additionally strapped to
non-returnable pallets. (Picture 1)

6.2 Single formliner rolls

Up to a length of approx. 1.50 m the cardboard rolls can be lifted by placing the fork
or forks of the fork-lift into the cardboard
tube. For rolls of formliner in excess of
1.5 m it is necessary to use extension forks
or a carpet spike as otherwise the forks
would pierce the cardboard roll and probably the liner as well. If using a crane for lifting make sure you use wide nylon lifting
straps evenly distributed along the length of
the roll. Do not use wires ropes or chains.
For large size formliners it can be useful to
place a steel tube through the cardboard
roll, make sure you use separate lifting
straps from each pole end to crane hook to
ensure even lifting. (Picture 3)

7. Heat Resistance
The formliners can used in temperatures up
to + 65 C. Temperatures which exceed this
value will damage the material. Should you
expect a concrete temperature on the interface to the formliner of more than + 65 C
due to the concrete mass or other circumstances the mix design or other suitable
actions should be adjusted to allow for the
safe use of the formliner within its temperature constraints.

Table 1
Depth of structure*
Maximum size*
Type of elastomer
Re-uses
Kind of delivery

Formliners 1 / ..

Formliners 2 / ..

> 25 mm
approx. 1.00 m x 5.00 m
light c = 0,9
50 times
Packed flat

1 - 25 mm
approx. 4.00 m x 10.00 m
normal c = 1,4
100 times
Rolls

* The exact sizes you find in our catalogue under the photos of the pattern.

8. Pattern Design

9. Cutting

There is no intended repeatability (with the

exception of any of the rib type patterns) in
the formliner patterns within the maximum
mould size as compared to wallpapers. A
number of patterns are designed in a way
that they can be placed together side by
side continuously. With a little care the joints
in the patterns can be made almost invisible. (Picture 4+5)
For the building of our master moulds we
use a combination of natural and man made
materials of commercial grade quality which
are formed using current standard working
practices. Unavoidable tolerances, discrepancies and imperfections caused by the
use of these materials can and will be
reflected in the patterns of the formliners.
The measurements shown in the sectional
drawings under and beside the pattern
photos in our pattern book are average
values and nominal dimensions which have
the stated tolerances. In using these sizes
for the calculation of your requirements you
should not expect that there is an equal
repetition of measurements within the same
formliner. The same criteria will apply
whether you place two full sizes sheet formliners together or two or more made to
measure (smaller) formliners.
Therefore it is possible that you will have to
stretch or compress the formliners to adapt
them to the required pattern format or shutter/mould measurements. This may be
required especially for patterns and textures for formliners of bricks, blocks, boards,
ribs etc.
It is essential that attention be paid to both
pattern sequence and direction of all designs; especially when concrete elements
are to be arranged side by side or one upon
another and are to appear seamless.
Unintentional rotation of the formliners by
180 for example can lead to conflicting
pattern effects.

9.1 Oversize and tolerances

Due to their high elasticity the formliners will
be stretched or compressed during packing
and transport which can lead to dimensional tolerances. Therefore, to protect the
liner edges against damage we always supply the formliners oversized. They must be
cut to their final dimension on site. It is
always advisable to cut formliners a couple
of millimetres longer than required for a
tight fit against the formwork guide battens.
(see 10.1)
The formliners should be cut to their final
size directly before adhering to avoid size
changes by stretching or shrinking due to
temperature differences.
As with all highly elastic rubber-like materials the formliners are subjected to stretching after a long period of use. Therefore it
may be necessary to re-cut the formliners
to their original dimension from time to time.
This of course will only apply if the formliners are not fixed by gluing.
Despite the most carefully controlled production process, dimensional tolerances of
some mm in the rear wall thickness of the
formliners is unavoidable. This is due to
material and production factors which we
are unable to negate. These dimensional
differences are unavoidable whether you
have a formliner produced in its maximum
size or a smaller made to measure formli-

ner within the maximum size of the same

formliner. Therefore it may be necessary to
grind the formliners edges to even and level
them or to thicken the seam area with
RECKLI-Formliner Adhesive or RECKLIElasto Filler when required to place them
horizontally next to another formliner. (see
20.2)
9.2 Formliners with prefix number 1/..
These formliners are normally supplied in
fixed widths whereas the length/height (ld)
is variable. If you have to put 2 or more formliners together (side by side) to reach a total
area for the shutter or mould, cutting will
probably be necessary. To make perfect
cuts lay the formliners onto a flat, clean even
surface and cut them using a suitable hand
panel or circular power saw. (Picture 6) If
using a power saw it is most important to
allow the saw blade to rotate freely into the
cut and during the cut. Keep the sawn material (waste part) pulled away from the blade
to avoid it flapping against the rotating saw
blade, otherwise heat will be generated and
the formliner can burn. On long cuts it is a
good idea to pull the power saw away from
the cut and let the saw spin under power to
dissipate any build-up of heat.
9.3 Formliners with prefix number 2/..
Roll out these formliners onto a flat, clean
even surface and cut them with the

RECKLI- Formliner Knife. For a straight cut

line please use a metal or timber straight
edge. (Picture 7)
When cutting thicker pattern formliners do
not try and make the cut in one place the
knife in the first cut and draw through the
formliner gently as many times as required,
do not use excessive force as this will lead
to crooked cuts. We do not advise cutting
these formliners with a circular power saw.
Note: It is very difficult to make mitred, bevel
cuts with a knife to an unfixed formliner.
When such bevels are required we can suggest two methods: a) place the area to be
mitred onto a board, place another board
above the formliner and fix thereby compressing the formliner. Set the power saw to
the required angle and depth and cut the
board and the formliner together. (Picture
8+9) b) Perform this task with a power saw
min. 24 hours after the formliner has been
adhered. Cutting the fixed formliner and the
plywood will give a more precise finish. We
also advise the 24 hour delay for the drilling
of any tie-bolt holes.

10. Application in
Pre-cast Concrete
10.1 Fitting the formliner
to the formwork or mould
After cutting the liner lay it loose into the
formwork/mould frame. The formliners with
prefix number 1/.. should have been cut

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with an over-size of 1-2 mm. So that you

can compress them into the dimension
frame for getting a tight compressive fit all
round.
The liners with prefix number 2/.. should
also be cut to an oversize of 1-2 mm. It is
easy to compress them so that they will be
a tight fit around the edges of the formwork/mould. Please Note: When you allow
too much oversize, the formliner will bow
up at the edge and form an air cushion
which even the pressure of the concrete will
not flatten. These air cushions will lead to
indentations in the concrete surface.
10.2 Fixing by adhering
Loose formliners have to be refitted into the
mould after every cast. To avoid this you
can glue the formliner on to the tilt-up or
vibrating tables (see 12.) This is always an
advantage when you have to produce a
series of elements of the same size. Loose
formliners will also be more prone to
stretching from their constant handling.
10.3 Setting & Placing the
formwork/mould edges
You can of course place your formwork/mould dimension frame directly on to
the formliners which have shallow patterns
or textures of approx. 1-2 mm. Patterns with
a depth of up to 5 mm can be sealed sufficiently by a compression band. For deeper

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patterns we suggest you make pattern

stop-offs (see 19.2) or in symmetrical patterns (ribs or waves) you can use the same
formliner piece inverted. (Picture 10)
Please Note: If the frame is pressed too
firmly on to the formliner for too long, there
will be a permanent depression in the formliner giving a noticeable difference to the
pattern if and when the frame has to be
moved to a different part of the formliner.
10.4 Vibration
It is possible that the frequencies of an
external vibrator can make the formliner
flutter and draw air under the formliner.
This can result in air cushions or bubbles
in the formliner which can lead to indentations in the concrete surface. Therefore the
vibrator and its vibration frequency must be
checked and adjusted correctly.
10.5 Stripping/Striking
Formliners that are laid loose in the mould
are generally removed from the concrete
elements and replaced back into the
moulds ready for reuse. Care should be
taken during the stripping/striking process
that the formliner will not fall off the concrete element when the tilting table is in the
vertical. The formliner would almost certainly be damaged. (Picture 11-13) To avoid this
happening you can glue the liners onto the
formwork/tilting table. (see 12.)

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11. Application for

In-situ Concrete
11.1. Fixing by adhering
When used for in-situ concrete the formliners must be glued down. (see 12.)
11.2 Fixing by nails
For minimum use or the immediate change
of shutter sizes after the first pour, the formliners with prefix number 1/.. can be nailed
onto the formwork. The nail centres should
be approx. 20-25 cm. Use lost heads or
ovals nails so that it is possible to pull the
nail heads through the formliner during
stripping/striking. Depending on the pattern
or texture always nail through the high
points of the pattern. This will ensure that
nail holes are in the negative part of the
concrete and not so easily noticed.
The formliners with prefix number 2/..
should not be nailed to the formwork. Due
to the weight of the formliners there would
be too much weight placed on the nails
when lifted into the vertical position and this
can result in the formliner tearing.

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The easiest surface to glue on to is the horizontal surface. Other shutter/mould applications which you might encounter might
be inclined, (Picture 17) half or quarter
columns etc. On vertical or rounded surfaces the adhesive would flow down to the
lowest point leaving insufficient adhesive for
a complete fixing. In these applications the
Formliner Adhesive should be thickened
with our RECKLI-Standardiser 100 to make
it more pasty. Please ask for our special
advice.
On inclined or vaulted surfaces the formliners can slide on the adhesive because of
their weight and the adhesive is not a
contact adhesive. Therefore the formliner
must be clamped, propped or pinned with
laths to the formwork/mould until the adhesive has cured. It is easier to add the
clamps and laths incrementally as you work
round the curve or radius.
You should not walk on or kneel on a freshly adhered formliner as this will push away
the adhesive under the formliner and can
result in dents in the formliner and show itself as circular raised areas in the concrete.

12. Adhering
Please Note: It can be to your advantage to
glue the formliners onto plywood sheets
and use these sheets as auxiliary/slave
formwork which you can then fix onto your
load bearing formwork or casting table. The
plywood can be fixed from the rear using
wood screws. The plywood can easily be
removed from the load bearing formwork
after use. It will also be easier to store and
dispose of the formliners when they are
glued to plywood.
12.1 Principles of fixing
RECKLI-Formliners must adhered completely. Point or spot gluing will lead to stretching of the formliners during stripping/striking. This type of stretching will lead to raised round areas in the formliner which will
show itself as dents in the concrete.
It is possible to glue on to steel as well as
on timber. Note: For adhering to steel use
our RECKLI-Primer MK. (see 12.3.2.1)

12.2 Adhesive
RECKLI-Formliner Adhesive is not a contact
adhesive. It is a 2-component adhesive. The
mixing ratio is 8:1 by weight. If it is necessary to weigh out smaller quantities of
adhesive this must be done by weight. For

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16

mixing the adhesive a slow speed electric

drill with the correct mixing paddle should
be used. (Picture 14) The base solution must
be mixed first. The hardener is then added
to the base solution and mixed thoroughly.
To avoid any soft spots or uncured material the adhesive must be placed into another
empty, clean container and mixed again.
(Picture 15+16) You should use only as
much adhesive as you can work with within
the pot-life. The pot-life depends on the
ambient temperature but as a rough guide
you will have approximately 10-15 minutes
at 18-20 C. Adhesive consumption is
approx. 750-1000 g/m2. After 24 hours the
adhesive is cured. You should give a longer
curing time during winter periods with lower
temperatures. The formwork, mould or the
tilting table can now be used.
12.3 Surface / Formliner rears
All surfaces that you wish to adhere to must
be even, clean and dry. Any grease, oil or
mud should be sanded off the shutter not
washed off. A superior bonding of the formliner to the shutter will be achieved if you
sand the rear of the formliners. (Picture 18)
A light sanding which will roughen the surface will be sufficient. In every case the
formliner backs must be cleaned by washing with RECKLI-Formliner Cleanser before
gluing. (see 12.4.1.1 and 12.4.2.1)

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12.3.1 Timber
The most suitable foundation for RECKLIFormliners are new clean untreated
plywood sheets designated as suitable for
shuttering. (Picture 19) With coated plywoods such as EVANS Pourform and
WYSEFORM please refer to RECKLI for
advice.
12.3.2 Steel
Steel must be rust free and the work will
benefit from a light sand-blast. If this is not
possible the minimum should be the use of
an angle grinder to the surface. In any case
steel must be primed with RECKLI-Primer
MK.
12.3.2.1 Priming
When adhering/gluing onto steel surfaces
RECKLI-Primer MK must be used. It can be
brushed or rolled on to the steel surface.
Allow approx. 30-60 minutes drying time
depending on ambient temperature and air
circulation before mixing and applying
RECKLI-Formliner Adhesive. A practical
indication of when the Primer MK is ready
for use is to test for tack with your fingers,
if the Primer MK shows tackiness and does
not disturb the film of primer on the steel
surface then it is safe to apply Formliner
Adhesive. If you exceed the drying time you

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will have to wait approx. 24 hours for the

Primer MK to dry properly then you will
have to sand the dried Primer MK to roughen its surface.
12.3.2.1 Properties of
RECKLI-Primer MK
Primer MK is a 2-component material. The
mixing ration is 4:1 by weight. If you need to
mix smaller quantities from the drum or can
you must weigh out the quantities. You
should never portion out the material by
volume. Add the hardener to the base material and mix thoroughly. To ensure complete
mixing pour the Primer MK into another
empty container and mix again briefly. You
can now apply the primer onto the steel
surface with brush or roller. The pot-life is
approx. 24 hours. The consumption rate is
approx. 150 g/m2.
12.4 Adhering
12.4.1 Formliners with prefix number 1/..
12.4.1.1 Cleaning
Lay the formliners onto their patterned surface for cleaning the rear. Take a clean cotton rag and soak it with RECKLI-Formliner
Cleanser to clean the rear of the liner. To
obtain a thorough cleaning of the formliner
do not reuse dirty rags. When the cleanser
has evaporated (approx. 15 minutes depending on temperature and air circulation) you
can start the adhering. You can hasten the
drying time by wiping the rear with a clean
dry cotton rag.
12.4.1.2 Checking dimensions with a
Dry run
Lay the liners loosely onto the surface to be
adhered, adjust them and check against
your measurements. Lay out a temporary
right angle on to your shutter/mould and lay
the liners against this frame. Remove and
stack the formliners onto a clean surface.

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12.4.1.3 Adhering/Gluing
After mixing the RECKLI-Formliner
Adhesive (see 12.2) pour it onto the surface
to be glued and spread the adhesive evenly over the surface using the supplied serrated trowel. (Picture 19+20) Take care that
you spread the adhesive equally. Spread
only so much adhesive over the formwork
surface as you need for the gluing of one
formliner or that you can work with within
the adhesives pot life. Make sure that the
edges of the formliner have sufficient adhesive as this is the most critical area of stress
when stripping and concrete will always try
to enter at the edge of the glue line and get
behind the formliners. Lay the formliner
onto the fresh adhesive along the temporary right angle. (Picture 21) Please take care
that there are no air bubbles under the liner.
The best way to avoid this is by sliding the
formliner backwards and forwards on the
adhesive. Then apply the adhesive for the
next liner. Press the liner against the first
one making sure you coat the vertical surface of the first formliner with adhesive to
give a grout free join. (Picture 22) Any surplus that has been squeezed out can be
wiped off after fixing or left to dry and sanded down. Carry on in this order until you
reach your total shutter requirement. When
fixing the formliner onto the shutter check
that the formliners will reach the required
point on the shutter/mould. Use rips of
plywood / wood and pin down edges of
liner to prevent them from lifting. You need
gentle pressure on the edges for 24 hrs.
minimum. Nail through the liner into the
plywood. Note: Do not drive the nails home,
excessive pressure will raise the edge of
the formliner and take it out of contact with
the shutter. If using steel shutters use
weight on the timber/ply rips.

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12.4.1.4 Gluing onto vaulted or curved

surfaces
The formliners 1/.. are flexible and can be
deformed to various degrees to accommodate shutter and mould shapes but because they are flexible and have a spring
value you will have to support/contain the
formliners to the shutter/mould profile until
the adhesive cures. To reduce the spring in
the formliner you can cut kerfs in the rear of
the formliner which makes curving the formliner easier, on extreme curves you can cut
Vs in the back of the liner. The depth of
these cuts will depend on the thickness of
the formliner. Cut only into the rear thickness of the formliner do not cut near the
pattern thickness. (Picture 23+24)
12.4.2 Formliners with
prefix number 2/..
12.4.2.1 Cleaning
Before gluing/adhering the rear of the formliner must be cleaned. Lay the formliners
onto their patterned surface for cleaning the
rear. Take a clean cotton rag and soak it
with RECKLI-Formliner Cleanser to clean
the rear of the liner. To obtain a thorough
cleaning of the formliner do not reuse dirty
rags. When the cleanser has evaporated
(approx. 15-30 minutes depending on temperature and air circulation) you can start
the gluing/adhering. You can hasten the
drying time by wiping the rear with a clean
dry cotton rag. When the formlineris dry
turn the formliner back onto its rear side
and roll it up again on to the transport
jacket (cardboard roll) making sure that
formliner is in the right position to be rolled
out on to the Formliner Adhesive and
shutter. The use of the stripping jackets
will make it easier to move the formliners
around the working area.
12.4.2.2 Checking dimensions with a
Dry run
Roll the liner loosely onto the surface to be
adhered, adjust and check against your
measurements. If necessary mark reference
points on the shutter/mould. Lay out a tem-

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porary right angle on to your shutter/mould

and lay the liner against this frame. Roll the
liner loose onto the surface to be adhered
and straight and fit it exactly. Take note of any
pattern that has parallel ribs or grid details.

Now roll up the second half of the liner to its

middle until you reach where you have started spreading the adhesive for the first half
and repeat the first half procedure until you
reach the end of the second formliner half.

12.4.2.3 Adhering/Gluing
Mix the adhesive (see 12.2) pour it onto the
shutter/mould surface, spread the adhesive
with a serrated trowel. Lifting the formliner
by its stripping jacket, place it next to the
start of the vertical part of the right angle
setting out frame roll the liner slowly onto
the fresh adhesive.
Make sure that the edges of the formliner
have sufficient adhesive as this is the most
critical area of stress when stripping and
concrete will always try to enter at the edge
of the glue line and get behind the formliners. Please take care that there are no air
bubbles under the formliner.
For the fixing of large formliners or when
there is a shortage of manpower an alternative method of fixing you might employ
could be this. After the Dry-run roll up the
formliner again with the cardboard roll until
in the middle of the shutter. Then mix the
formliner adhesive (see 12.2) and pour it in
front of the rolled up half of the formliner
and spread it equally over a strip of approx.
75-100 cm along the length of the liner.
(Picture 25+26) An even and uniform
thickness of the adhesive is most important.
Check against excess adhesive which can
lay in pools. In moving the adhesive with the
serrated trowel you should look for the
distinctive tram-line effect on the adhesive
the shutter/mould surface should be clearly visible. Now roll the liner onto the fresh
adhesive and repeat the pouring, spreading
and rolling the liner along the shutter/mould
strip by strip until you reach the end of the
first liner half. Make sure that there are no
air bubbles under the formliner. Press out
the air to the front and the sides. During
fixing check that you are reaching your
datum/pattern points on the formliner or the
parallel running of ribs or joints if there are
any in the patterns.

12.5 Removal of glued formliners

When the formliner adhesive has been
mixed and applied correctly the fixing
should be considered permanent. The
removal of glued formliners should be considered a major task and would be very difficult to remove them from the
shutter/mould without damage to the formliner. Therefore it can be an advantage not
to glue the formliner directly onto the structural formwork but onto separate plywood
sheets as slave formwork and then to fix
these to the structural formwork.
If it is absolutely necessary to remove formliners from the shutter/mould you can use
the peel-off method. Cut in at the glue line
on one corner pulling the formliner up and
cutting away at the glue line carry on until
you have a large enough piece of formliner
to attach a clamp to which can be attached
to a crane, fork lift etc. to apply more force
while cutting away at the glue line. Any residue can be sanded off the shutter and
formliner with a belt sander.

26

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28

13. Release Agents

13.1 Choice of release agent
The choice and application of the correct
release agent is most important to obtain an
efficient release and high a quality concrete finish. We supply three different release
agents depending on the application.
RECKLI-Stripping Wax TL contains solvents. RECKLI-Stripping Wax TL-W is
water-based. These two release agents are
more suited to pre-cast concrete. RECKLIStripping Wax TL-SO also contains solvents
and is especially designed for in-situ
concrete. (Table 2)
13.2. Application
The stripping wax must be brushed or
sprayed on a minimum two times.
(Picture 27) The release agent should be
applied laterally and longitudinally. It is most
important that in any rib patterns the
vertical part of the ribs should be sprayed at
45 from both sides of the formliner to ensure correct coverage. Surplus wax must
be removed by a brush or clean cloth. You
can also blow it off with compressed air.

29

13.3 Protection of the wax film against

weathering
After evaporation of the solvents in
Stripping Wax TL and TL-SO or the drying
of the water-based Wax TL-W you can use
the formliner/mould. To avoid any damage
by rain and weather to the wax film you
should protect the liners with polyethylene
or any light plastic covers. (Picture 28) If the
wax film has been reduced or damaged it
should be reapplied.
Note: You will find that a fan spray will give
the best and most even application of the
Stripping Waxs TL and TL-SO. Make sure
that your sprayer has solvent resistant gaskets.

14. Bar spacers

Bar spacers that offer the largest contact
areas should be used. Chair type spacers
give a point loading and will press into the
formliner (Picture 29) and will therefore
show through the concrete. The minimum
concrete covering over the reinforcement is
always measured from the deepest point in
the concrete surface. Therefore the bar
spacers must be set onto the highest points
of the formliner pattern.
It is of great advantage to hang up the reinforcement for avoiding a loading of the
liners. (Picture 30)

15. Concrete Casting

RECKLI-Formliners allow the use of all
types of cement based concrete. When
using external vibrators you should note
that some of the vibration frequencies will
by absorbed by the elasticity of the formliner. This can be compensated for by a longer vibration time.

Table 2
Application

Type

Consumption per coat

Pre-cast concrete

RECKLI-Stripping Wax TL
contains solvents
RECKLI-Stripping Wax TL-W
water-based
RECKLI-Stripping Wax TL-SO
contains solvents

50 -100 g/m2
2 coats required
50 -100 g/m2
2 coats required
50 -100 g/m2
2 coats required

Pre-cast concrete
In-situ concrete

30

31

32

33

16. Striking / Stripping

17. Cleaning

16.1 Striking / Stripping timing

It is easier to release RECKLI-Formliners
within 24 hrs of casting. Specification and
striking times for your particular application
should overrule RECKLI`s suggestion.

17.1 Formliner surfaces

When the formliners are provided with the
correct amount of Stripping Wax the formliner will be clean and ready for reuse after
striking/stripping, reapply more Stripping
Wax ready for the next cast. If, for any reason it becomes necessary to clean the
formliner, take a dry, clean rag and soak it
with the relevant Stripping Wax and clean
off any cement splashes or dirt on the formliner. Please do not use RECKLI-Formliner
Cleanser for this work. RECKLI-Formliner
Cleanser is only suitable for cleaning the
rear (fixing side) of the formliners before
gluing.

16.2 Unfixed formliners

Formliners that are laid loosely in the mould
will peel off of the concrete during stripping
due to their weight. (Picture 11-13) If this
should not happen due to the depth of
pattern, peel off the liners carefully starting
from a corner. Do not tear at the formliner,
doing so could exceed its stretching
capacity
16.3. Adhered formliners
Release the pre-cast concrete elements
from their moulds or the shutter from the
concrete. The releasing of the element from
the mould or the shutters from the concrete
should be done slowly and carefully. You
must allow the formliners time to stretch and
release themselves from the concrete they
should need the minimum effort from you.
(Picture 31-35) In every instance avoid the
use of sharp or edged tools to hasten the
stripping process as damage will be done
to the formliners.

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10

35

17.2 Tools and equipment

For cleaning tools and equipment after
use, use RECKLI-EK-PU Thinner. Clean
thoroughly while the formliner adhesive
is fresh. Use a brush, it is not sufficient to
lay the tools in the thinner. You will not be
able to remove the cured 2-component
material once it has hardened. For cleaning
tools you can also use RECKLI-Formliner
Cleanser. But this cleanser is not so effective as RECKLI-EK-PU Thinner.

36

37

38

18. Joints / Corners / Edges

18.1. Use of profiled fillets
Profiled fillets for shaping corners, edges
and joints should be considered. You must
calculate the thickness of the profile as to
what part of the pattern it is required to be
aligned to i.e., top, middle or bottom. The
thickness of the formliner back must also
be considered. (see sketch 1-5) (Picture 3639)

formliner

Butt joint

Sketch 3

formliner
formliner

Chamfered cove, high in concrete

Sketch 1

Smooth frame with chamfer deep in concrete

Sketch 4

formliner
formliner

Chamfered cove, deep in concrete

Sketch 2

Smooth frame with chamfer high in concrete

Sketch 5

11

39

40

18.2 Formliner joints

When placing formliners with coarse or
rank patterns side by side care must be
taken to see that the joints from this operation are sealed correctly. RECKLI-Formliner
Adhesive can be used after you have glued
the formliner down. You can also use
standard building One Component Silicone
applied to the formliner when the adhesive
has cured. We do not advise butting or
mitring formliners together for 90 corners
for such kind of patterns. They will never
look good. Make a feature at the corners by
introducing a plain band to the pattern, the
corner will look sharper and straighter. The
formliner will also have a straight line to
finish to. (see sketch 6-9)
Of course for patterns with straight lines
like ribs and waves it is of advantage
to cut the liners mitred for 90 corners.
(Picture 40+41)

41

formliner

Cove with chamfer, high in concrete

Sketch 7

formliner

Cove with chamfer, middle in concrete

Sketch 8

formliner

Chamfer in formliner

Sketch 6

12

formliner

Cove with chamfer, deep in concrete

Sketch 9

42

19. Stop-offs / Counter

impressions
19.1 Cuts out
Pattern stop-offs for i.e. windows, doors or
lighting can be formed by cutting out the
shapes in the formliners and inserting a
frame. This is suitable if the same openings
are to be used in the same position for
every use of the formliner. (Picture 42)
19.2 Pattern stop-offs using
RECKLI-Mould Paste PU
If they are to be used once or twice or the
formliner needs to be used in a different
position then RECKLI-Mould Paste PU
should be used. (Picture 43+44) Select the
area for the pattern stop-off and paint on
RECKLI-Mould Wax exceeding the area by
at least 100 mm all round. On textures, shallow patterns deep ribs place a frame larger
than the required stop-off. Use clay or
Plastercine to fill in the space between the
bottom of the frame and the pattern detail.
On deep rib patterns, to save material block
off with timber pieces. Paint the frame, clay,
Plastercine with a coat of Mould Wax. Mix
and pour the Mould Paste PU inside the
frame forcing the material into the pattern
detail with a spatula. You can mix and pour
wet on wet material to reach the required
level which should be approx. 6mm higher
than the highest part of the pattern. Place a
clean dry board onto the fresh Mould Paste
PU making sure it is level. Leave to harden.
When hardened remove from formliner and
trim off surplus material for sharp square or
cut bevelled edges.

43

19.2.1 Properties of
RECKLI-Mould Paste PU
RECKLI-Mould-Paste PU is a pasty elastic
2-component material. The mixing ration is
10:1 by weight. If using only part quantities
from a drum the amounts of base solution
and hardener must be weighed out, never
mix by volume. For mixing use a slow speed
electric drill with the correct mixing agitator.
Mix only so much paste as you can work
with within the pot-life. The pot-life is
approx. 10-15 minutes depending on temperature. The curing time is approx. 1 hour.
The consumption depends on the type of
pattern. The specific weight is approx.
1.4 g/cm3.
19.2.2 Removing of mould wax residues
To avoid different colours in the finished
concrete, the area treated with RECKLIMould Wax must be removed and cleaned
by using RECKLI-Stripping Wax. Soak a
clean cloth with RECKLI-Stripping Wax TL,
TL-SO or TL/W and wash and clean off the
areas where the Mould Wax remains. If this
procedure is not carried out carefully,
colour differences in the finished concrete
surface should be expected.
19.3 Inverted formliners
For symmetrical patterns (ribs or waves)
you can use the same formliner pieces
inverted for stop-offs. (Picture 10)

44

20. Repairing / Patching &

Equalizing of Formliners
20.1 Repair
With RECKLI-Elasto Filler you can patch
and repair damaged or torn formliners. To
get a correct bonding of the Elasto Filler to
the formliner the damaged area holes or
tears must be clean, dry, dust, oil, wax and
grease free. The area to be repaired or filled
must be roughened by sand paper. The filler must be applied quickly and within the
pot life time. Surplus material must be
removed while the material is still fresh.
Texture and shape modelling must be done
also within the pot-life. Any hardened residue can be ground off after approx. 2-3
hours. After 4-5 hours you can load the
repaired area.
Tears and splits: Carefully clean and pretreat the sides of the split or tear as above
mentioned. Under the tear lay a piece of
polyethylene to avoid unwanted bonding of
the paste. Apply RECKLI-Elasto Filler to the
sides of the tear and press the tear together.
Surplus filler can be removed with cloth or
spatula and is best removed while fresh.
Cured filler you can only remove by sanding
or cutting. After curing turn the liner on to its
front side. Grind out 3-5 cm left and to the
right of the tear line and approx. 3 mm
deep. Fill this recess with the Elasto Filler
and smooth it. After 2-3 hours hardening it
can be ground level. Turn the formliner back
onto its rear and apply RECKLI-Stripping
Wax to the repaired area.
Note: We must categorically point out that
a repaired seam cannot possibly give the
same result as an undamaged formliner.
There is always the possibility of the
repaired formliner tear showing through in
the patterned surface even when the repair
has been carried out extremely careful.

13

45

20.1.2 Properties of
RECKLI-Elasto Filler
RECKLI-Elasto Filler is composed of
2 liquid components. The mixing ratio is
8:1 by weight. After mixing the hardener
with the base component a thixotropic
action will take effect after about 2-3 minutes. The thixotropic effect increases until the
end of the materials workable time. In this
time RECKLI-Elasto Filler can be used as a
pourable material and as a filler. The pot-life
takes approx. 10 minutes at + 18 C. The
layer thickness can be up to 10 mm in one
application. Consumption depends on the
area to be repaired. The specific weight is
approx. 1.4 g/cm3.
Note: To extend the workable time of Elasto
Filler spread the mixed filler onto a board as
a thin coat.
20.2 Equalizing of formliner rears
As already mentioned (see 9.) dimensional
tolerances of some mm in the rear wall
thickness of the formliners is unavoidable.
(Picture 45) Therefore, sometimes it is
necessary to adjust the thickness of the
formliner rear. This you can do by grinding
down the thicker one or by increasing the
thickness of the thinner one. Turn the liners
on to their pattern sides put them together
and grind or sand down the thicker parts
along the edges in a flat strip until you have
reached the thickness of the thinner formliner. (Picture 46) Be sure to 'feather' away
the grinding or sanding to the centre of the
formliner so that you do not leave a step.
When the difference of the rear thickness is
too big, it could be easier not to grind the
formliner down but to increase the thickness of the thinner one. Turn the liners on to
their pattern side. Clean the area to be
levelled by grinding or sanding this also
acts as preparing the foundation. Place a
piece of timber along the edge to be levelled to the required height. Paint the board
with RECKLI-Mould Wax allow to dry and fix
along the formliner edge which you wish to
fill level. Mix the RECKLI-Formliner
Adhesive (see 12.2) and pour it onto the
roughened rear part of the formliner.
14

46

47

(Picture 47) Being a liquid it should find its

own level. Take RECKLI-Elasto Filler (see
20.1.2) for the levelling material when the
area to be levelled is not too large. (Picture
48) After the Formliner Adhesive or the
Elasto Filler has cured remove the board
along the formliner edge. If necessary
grade the repair into the formliner by grinding or sanding which will also remove any
high spots. The formliner is now ready for
use. (Picture 49)

21. Waste disposal

RECKLI-Formliners are made from Polyurethane Elastomers. The code of the
European Waste Register is 12 01 05.

48

49

22. Product & Consumption Table

22.1 Material Please refer to the relevant technical pamphlets, too.
Material

Application

Consumption

RECKLI-EK-PU Thinner
RECKLI-Elasto Filler

Cleaning of tools and equipment

Repair of damaged formliners
and equalizing of formliner rears
Adhesive for full entire surfaces on steel
or timber and equalizing of formliner rears
Cleaning of formliner rears or
damaged spots or fractures and tools
For making pattern stop-offs
Release agent for RECKLI-Mould Paste PU
and for steel or timber gauges while
equalizing of formliner rears
Primer before gluing on to steel
Thickener for Formliner Adhesive
for gluing on vaulted or curved surfaces
Release agent for pre-cast concrete,
contains solvent
Release agent for in-situ concrete,
contains solvent
Release agent for pre-cast concrete,
water-based

Depending on the degree of contamination

depending on the volume of damage
or filling, c = 1.4
Approx. 750-1000 g/m2

RECKLI-Formliner Adhesive
RECKLI-Formliner Cleanser
RECKLI-Mould Paste PU
RECKLI-Mould Wax

RECKLI-Primer MK
RECKLI-Standardiser 100
RECKLI-Stripping Wax TL
RECKLI-Stripping Wax TL-SO
RECKLI-Stripping Wax TL-W

Approx. 100-200 g/m2 or depending

on the degree of contamination
Depending on the pattern, c = 1.4
Approx. 150-200 g/m2

Approx. 100-200 g/m2

1-5 %
Approx. 100-150 g/m2
depending on the pattern
Approx. 100-150 g/m2
depending on the pattern
Approx. 100-200 g/m2
depending on the pattern

22.2 Tools / Equipment

Tool / Equipment

Application / Use

Boards / rips / laths

Restraining of formliner during and after adhering, boards for pressing into
Mould Paste PU for stop-offs
Application of Primer MK / Cleaning tools
To decant after mixing 2-component material in original container
Removing residue of adhesive film / grinding rear of formliner for better bonding /
grinding of recesses for strengthening of repaired tears / equalizing of formliner rear
Cleaning the rear of formliners / removing of Mould Wax residues while using
Mould Paste PU
Scraping material from pails or drums
Cutting of formliners index 1/.. and pattern stop-offs
Marking of stop-off lines
Straight edges for cutting liner index 2/..
For electric hand drilling machine for mixing 2-component material
Protection of formliners and Stripping Wax application against weathering
Cutting of formliner index 2/..
Cleaning and sanding of formliners / removal of surplus Elasto Filler and levelling
of repaired areas
To apply pressure to boards while Formliner Adhesive cures / clamp preparation
for peeling off of glued formliners
Spreading of Formliner Adhesive
Mixing of 2-component material
Mixing and application of Elasto Filler, cleaning and pointing joint lines and smaller
quantities of Formliner Adhesive
Application of Stripping Wax
Peel off of adhered liners from form-work
Checking of formliner measurements
Weighing out of smaller quantities of 2-component materials

Brush / roller
Buckets
Circular grinder / belt grinder
Cloth / rags
Gauging/pointing trowel
Hand circular saw
Marker-pencil
Metal / wood straight edges
Mixing paddle
Polyethylene
RECKLI-Formliner Knife / hand panel saws
Sandpaper
Screw clamps
Serrated trowel
Slow speed electric hand drill
Spatula
Spray
Stanley or RECKLI-Formliner Knife
Tape measure
Weighing scales

15

RECKLI-Chemiewerkstoff GmbH
Adresse/Address:
Eschstrae 30
D-44629 Herne Germany Tel. ++49 / (0) 23 23 /1706-0 [email protected]
Postadresse/Mailing Address: Postfach 1013 29 D-44603 Herne Germany Fax ++49 / (0) 23 23 /1706-50 http://www.reckli.de

1111 / 10/03 / RW

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