A shallow foundation form and method of using are provided. The form is useful for pouring concrete slab foundations and results in a frost protected foundation with improved thermal characteristics. The form may include brackets to hold rebar at various locations. The brackets are designed to avoid the use of fastening devices, such as wire ties. When used to pour a concrete foundation, the form and brackets reduce construction material input costs, reduce the amount of skilled labor required, and reduce the amount of time required to pour a foundation.

A system for retaining a flowable and curable building material to form a portion of a foundation includes side walls disposed in a predetermined configuration having a first side wall and a second side wall, and at least one component having an interior cavity disposed in one of the side walls. A bracket assembly includes an outwardly bounding reinforcement post for each of the side walls, a separator bar having a plurality of apertures sized to receive and retain each of the reinforcement posts at locations corresponding to nominal widths of the at least one component. A barrier is disposed between the outwardly bounding posts. The barrier and the component in the side wall is retained in the foundation after the building material cures. The barrier prevents backfill from filling a volume between the outwardly bounding posts.

A system for retaining a flowable and curable building material to form a portion of a foundation includes side walls disposed in a predetermined configuration having a first side wall and a second side wall, and at least one component having an interior cavity disposed in one of the side walls. A bracket assembly includes an outwardly bounding reinforcement post for each of the side walls, a separator bar having a plurality of apertures sized to receive and retain each of the reinforcement posts at locations corresponding to nominal widths of the at least one component. A barrier is disposed between the outwardly bounding posts. The barrier and the component in the side wall is retained in the foundation after the building material cures. The barrier prevents backfill from filling a volume between the outwardly bounding posts.

In exemplary implementations of this invention, a nozzle sprays foam, layer by layer, to fabricate a fabricated object according to a CAD model, and a subtractive fabrication tool removes material from the fabricated object according to a CAD model. The fabricated object comprises a mold or an interior form. The foam may be low-density, high strength and fast-curing. The foam may be used for large-scale 3D printing. For example, the foam may be used to 3D print molds for walls of homes. The foam molds may be left in place, after casting concrete in the molds, to serve as insulation. Or for example, the foam may be used to 3D print on site an internal form for a large wind turbine blade. The wind turbine blade may then be produced on site by depositing fiberglass on the outside of the internal form.

In exemplary implementations of this invention, a nozzle sprays foam, layer by layer, to fabricate a fabricated object according to a CAD model, and a subtractive fabrication tool removes material from the fabricated object according to a CAD model. The fabricated object comprises a mold or an interior form. The foam may be low-density, high strength and fast-curing. The foam may be used for large-scale 3D printing. For example, the foam may be used to 3D print molds for walls of homes. The foam molds may be left in place, after casting concrete in the molds, to serve as insulation. Or for example, the foam may be used to 3D print on site an internal form for a large wind turbine blade. The wind turbine blade may then be produced on site by depositing fiberglass on the outside of the internal form.

Features for formliners to form a decorative pattern in a curable material and methods of using the same are disclosed. An improved formliner is disclosed with substantially seamlessly connecting components that reduces the need for using adhesives for interconnecting a plurality of formliners in a pattern. Further, the formliner is configured to reduce and/or substantially eliminate visible seams in order to create a more natural appearance in a finished product of the curable material.

A sealing structure for the bottom of a beam space between precast panels, comprising: a first precast panel and a second precast panel substantially aligned to each other along a single plane and spaced from each other by a space, each of the first precast panel and the second precast panel defining an inner edge adjacent to the space; a soft pad abutting the space for sealing a bottom of the space; a plate abutting the soft pad; a fastening device securing a first side of the plate and a second side of the plate to the first precast panel and second precast panel, respectively, so as to assist the soft pad in the sealing of the bottom of the beam space; wherein the fastening device does not contact the soft pad.

A sealing structure for the bottom of a beam space between precast panels, comprising: a first precast panel and a second precast panel substantially aligned to each other along a single plane and spaced from each other by a space, each of the first precast panel and the second precast panel defining an inner edge adjacent to the space; a soft pad abutting the space for sealing a bottom of the space; a plate abutting the soft pad; a fastening device securing a first side of the plate and a second side of the plate to the first precast panel and second precast panel, respectively, so as to assist the soft pad in the sealing of the bottom of the beam space; wherein the fastening device does not contact the soft pad.

A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. Thus, a plurality of formliners can be interconnected by overlaying raised sections thereof. Further, the formliner can comprise one or more detents and one or more protrusions to enable engagement between interconnected formliners without requiring adhesives. In this manner, formliners can be interconnected in a nested manner such that visible seaming between the interconnected formliners is reduced and/or eliminated.

A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. Thus, a plurality of formliners can be interconnected by overlaying raised sections thereof. Further, the formliner can comprise one or more detents and one or more protrusions to enable engagement between interconnected formliners without requiring adhesives. In this manner, formliners can be interconnected in a nested manner such that visible seaming between the interconnected formliners is reduced and/or eliminated.