One of the services we offer to our clients is the design and manufacture of timber moulds. These sustainable options allow builders to create builds with very specific requirements and to suit client requests. There are a host of reasons why these are the preferable option for many projects, including sustainability
What are timber moulds?
For us here at 3D Pattern and Mouldmakers, timber moulds refer to large or small-scale constructions that can be used to form concrete following the designs laid out by a client. They are manufactured to order, using the most up-to-date and advanced technology to ensure each component fits together exactly. Regardless of the reason a client notes for choosing timber as their primary material, we work closely with them to ensure the final project is completed to the highest standard.
What types of timber are used?
Predominantly, moulds are made from sawn redwood and lined in high-quality birch plywood. The carcass is generally a pallet construction, fully boarded using timber, the same technique being used to create the sides and ends of the mould but with straps used where the mould may be more than one board high as opposed to pallet construction. 4X3 timbers form the basis of the pallet and any straps connecting boards together for the height of the sides and ends and 8×2 is used for the carcass material.
Harvested from trees that lose their leaves annually, hardwoods are a popular timber option for any timber shaping needed for a timber mould. As the wood tends to grow at a slower rate, it is also denser which gives it additional strength. For this reason, hardwoods are usually used as they are less prone to damage during the precast concrete manufacture process.
We tend to use tulipwood which is extremely hard wearing and has few knots evident, this is of importance as it means there is less chance of an imperfection showing up on a precast item.
Benefits of hardwood in mould construction
As mould makers we need to ensure that the product ordered by the customer is going to stand up to the rigours of use, hardwood being stronger by nature is perfect for machining to various sections, some of which can be fairly small to create a false joint or drip detail for instance. But some of the key benefits of hardwood in timber mould construction are:
- Strong – Because they are slow-growing, hardwood is stronger than other woods.
- Value for money – Although hardwood timber features in moulds can be more expensive to manufacture, their longevity, easy maintenance and host of benefits means they are likely to be a better investment over time.
- Versatile – Timber is a very versatile material that can be cut and manipulated into specific shapes easily.
How are timber moulds made and used in construction?
Within construction, timber moulds are frequently used to form items of precast concrete or cast stone and now GFRC concrete. The use of these production materials is widespread and so too is the landscape into which they are used, the key that links them all together is offsite manufacturing. By planning at an early stage it is possible for a building to be erected much quicker than originally used to be the case, precast items produced from mould can be held as stock and called off when required by site. We are finding more and more that architects are pushing the boundaries, particularly on large panels which are rewarding for us as a company as it makes this job anything but mundane and supplying timber moulds which will eventually form a piece of cast stone that may end up in a prominent position is always hugely satisfying.
The wider application of timber moulds is vast and considering the types of unit cast from them for building work which will ultimately be visible, there are a great many uses for moulds to create items which may be hidden from site such as ducting or tunnel segments, for instance, add to these products that are on public view but perhaps don’t get much attention like bridge parapets, retaining walls and flood defence projects, timber moulds are certainly well used in construction across the board.
How do we create timber moulds
Here at 3D Pattern and Mouldmakers, we specialise in the design and manufacture of timber moulds for a variety of purposes. Using the most sustainable woods throughout, we work to the specific requirements of our clients.
Once we have a clear understanding of your requirements, dimensions and measurements, our teams get to work crafting the mould exactly. Once it has been produced, each mould part will be treated with 3 coats of polyurethane mould varnish. This ensures that the mould has an excellent finish and one that meets your exacting needs. We are also able to add in rubber gaskets to the construction which will significantly reduce the amount of grout loss.
With our 5 and 10-tonne gantry cranes, our teams are able to deliver larger items, including terrace units and ground beams, swiftly and conveniently.
Get in contact today
Timber moulds are one of the most specialist and popular offerings within our range of services. They are chosen by those seeking exceptional quality and versatility with their design. If you have any questions about these moulds or would like to discuss your individual project in more detail, get in contact with the team here today.