Can you provide additional information about "Building with the Site-Cast Concrete System" published in the July 1972 issue (page 324)? In past efforts to do site-casting we have had difficulty controlling the dimensions of the edge forms. For example when we attached forms (which happened to be metal) to the edge of a panel, as shown in the lower righthand picture of page 325, we found that a slight tilt in the form would cause each panel to be a small fraction of an inch larger than the one below it. By the time we cast the top panel in the stack the panels were considerably oversize. Do you have a good system for avoiding this problem?
The most critical stage of construction when building site-cast structures is during panel fabrication. This is where all the factors affecting economy and speed are primarily influenced. Dimensions must be accurate, and openings, rebar and conduit must be in the right place. Challenge Developments, Inc. uses its best layout carpenters at this stage. After the forms have been completed and checked by the layout men, they are completely rechecked by a representative of the architect who has been hired for this purpose by the builder and who spends full time on the job during the fabrication stage. To avoid the problem of continuously enlarging panels, bottoms of the side forms are installed so that they are a fraction of an inch above the surface of the previously placed panel. This permits complete adjustment of forms in a horizontal plane. Fins and leakage occurring as a result of using this method are removed by sandblasting the stacks after panel fabrication work has been completed. If side forms lap the previous panel edges, panel growth can occur. If the brackets being used to secure the forms do not adequately restrain the side form from bulging, wire ties across the full width of the panel can be used. This generally has not been found necessary.