We have extensive experience with concrete and have created bespoke cladding for Calgary homes since 2002. We value helping our clients realize the versatility of concrete. It’s a fascinating material that makes a hardy yet handsome façade for architecture. So, how do we turn raw concrete into a beautiful, functional material? Here’s how we do it at Sculptural Design.
First – Creating the Perfect Concrete Mix
We make our cladding from glass-fiber reinforced concrete (GFRC). It starts as a mix of cement, aggregate (small stones), water, polymers, and glass fibers—more on those later. The ratio of these elements is critical. The consistency when wet will affect its strength and durability after it dries. We custom engineer our mix to suit the requirements of each project.
Reinforcing the Concrete With Glass Fibers
All our concrete is reinforced with tiny glass fibers to make it stronger and more resistant to temperature changes. When the concrete is wet, we spray the glass into the panels using a specialized spray gun. The gun breaks the fibers into tiny shards and distributes them evenly among the concrete mix.
We spray this concrete and glass mix into our custom molds layer by layer, allowing sufficient time to dry between layers. Adding glass fibers to our concrete cladding panels increases their tensile strength, helping prevent cracks.
Hand Rolling or Hand Pressing
Once we have sprayed the concrete into the molds, we let it dry slightly but not to completion. While in this semi-cured state, we carefully compress it with a hand roller to remove excess water and air from the mix. Doing this makes the concrete less porous. Once dry, the hand-rolling technique creates a smooth, seamless surface for your concrete cladding panels.
Getting it Ready for You
The final step in our concrete casting process is to let everything dry thoroughly. The drying or curing duration depends on the style, thickness and size of the product. Once cured, we can install your new concrete cladding panels indoors or outside. For more information about our process or to get a quote for your project, please contact us.
