Abstract: Concrete forms utilizing a laminated concrete form liner including a porous fabric laminated to a drainage scrim. The laminated form liner is untensioned and used in combination with a support to form a concrete casting system wherein the porous fabric side of the laminated form liner is placed directly in contact with the concrete. The drainage scrim enhances the ability of the form liner to remove excess water from the surface of the concrete.

Abstract: Apparatus and method for attaching and bi-directionally tensioning a porous fabric over a flexible, rectangular form support. The frame comprises a pair of rigid, parallel frame members connected by a pair of parallel cross members. The ends of the frame members contain legs that contact the form support in each corner thereof. Suction cups located on the cross members allow the form support to be attached to the frame and pulled towards the frame such that the edges of the form support flex between adjacent legs. Once the form support has been flexed, the porous fabric is wrapped over and attached to the form support at the corners and along all sides. After the porous fabric is completely attached to the form support, the frame is removed so the form support can return to its flat unflexed, rectangular dimensions. The result is that the porous fabric is bi-directionally stretched over the form support such that a uniform tension of 50 to 300 kg/lineal meter is created.

Abstract: Apparatus for attaching and bi-directionally tensioning a porous fabric over a flexible, rectangular form support. A frame comprises a pair of rigid, parallel frame members connected by a pair of parallel cross members. The ends of the frame members contain legs that contact the form support in each corner thereof. Suction cups located on the cross members allow the form support to be attached to the frame and pulled towards the frame such that the edges of the form support flex between adjacent legs. Once the form support has been flexed, the porous fabric is wrapped over and attached to the form support at the corners and along all sides. After the porous fabric is completely attached to the form support, the frame is removed so the form support can return to its flat unflexed, rectangular dimensions. The result is that the porous fabric is bi-directionally stretched over the form support such that a uniform tension of 50 to 300 kg/lineal meter is created.

Abstract: A concrete form with provision for draining excess water and air from wet concrete by placing fabric over a grid on the support portion of the form. A patterned surface of increased hardness results from use of the form. One embodiment results in concrete with a completely smooth surface.

Abstract: Concrete forms utilizing a concrete form liner including a two-sided fabric having a different range of pore sizes on one side compared to the opposite side. In one embodiment, a microporous coating, such as an ethylene-vinyl chloride microfoam dispersion, is placed on one side of a porous fabric to controllably reduce the pore size of the fabric on that side to between 0.2 to 20 microns. The coated fabric is used in combination with a support and a grid to form a concrete casting system wherein the coated side of the fabric is placed directly in contact with the concrete. The microporous coating stabilizes the surface fibers of the fabric thereby reducing the tendency of the fibers to stick to the concrete. The pore size of the coated side of the fabric must be small enough to substantially keep all concrete particles from passing through the fabric, but sufficiently open to permit the passage of water and air.

Abstract: A process is disclosed for manufacturing a high strength composite structure by needling individual webs of initially spunbonded material and then needle-punching a stack of the individual webs to enmesh and entangle filaments across the webs, with little or no loss of the initial filament-related strength.