Casting Methods

The two methods for casting and installing the GibbarWALL Panels are precast on-site and precast off-site. The steps for each process are outlined below.

Method 1—Pre-cast / on-site

This method, which uses level ground as the casting bed, is the lowest cost method and very fast.

Step 1. Set up the forms on reasonably level ground.
Step 2. Place and compact material for the casting bed
Step 3. Lay down the foam liner, panel dividers, lift inserts, and rebar.
Step 4. Pour and finish. The panels can be stamped, stained, or treated with other finishes.
Step 5. Lift and install the panels
Step 6. Set the panels in place and support with bracing. The footings on this building were poured after the walls were set. It is also common to pour footings prior to setting the walls and welding in place.

Method 2—Precast off-site

Cast-tilt's typical method for casting and installing the structural “shell” for above grade or below grade buildings. This applies to both single or multi-story buildings.

Step 1. Select your preferred casting location. This project was cast on heated steel tables. One of the cautions with metal tables is the transferring of rust stain onto the pretty white insulation. It doesn't affect the performance of the walls, but it sure looks ugly when the wall are set in place. If you use steel tables, put a plastic barrier on the rusty surface before placing your insulation.
Step 2. Put the insulation in the formed panel. This takes only a few minutes for one man.
Step 3. Cut out window and door openings with a common Sawzall or hot knife. Again this only takes a few minutes to chalk some lines and cut the insulation.
Step 4. Insert the metal studs. This only takes a few seconds per stud.
Step 5. Set your pre-packaged windows or doors into the opening. We will show you how to assemble the package.
Step 6. Install reinforcement.
Step 7. Pour standard weight concrete.
Step 8. Deliver and set up the walls. Because the panels are almost half the weight of solid walls they can be installed before the footings and floor. This speeds up the overall schedule. The walls on this project were set in place prior to installing the footings, plumbing or electrical. Once the wall were in place the subs found it easier and faster to install their work.
Step 9. Pour the footings and floor.
Now you can begin installing other interior work.