Casting GFRC Concrete to Create Textured Shower Panels

Casting GFRC with Forton VF-774 to create shower panels. Multiple GFRC panels of different sizes and shapes will be made from this single texture mat mold to produce furniture, countertops and more.
Contents:
Preparing the Mold (00:29)
Panel Layout (01:02)
Mixing and Spraying GFRC Face Coat Mix (02:01)
Mixing and Applying GFRC Backup Mix (04:03)
Staining and Sealing the GFRC Panels (08:27)
Panel Installation (09:55)
Preparing the Mold (00:29)
A level casting platform is built. The rolled Mold Star 30 mold is brought from the job site. The mold is checked to ensure levelness. Excess dirt is blown off with compressed air.
Panel Layout (01:02)
Four panels will be produced. The four panels will be made on different sections of the same mold. 0.5" (1.27 cm) thick PVC boards will be used as form walls. The walls for the first panel are laid in rough position. Bracing is nailed to the casting platform. The form boards are carefully squared to make the first panel. Matching form boards are nailed at the top and bottom of the mold.
Mixing and Spraying GFRC Face Coat Mix (02:01)
The components are assembled. Type 1 Portland Cement and silica sand are dispensed by weight. Dry components are premixed. In a separate bucket, the liquid components are premixed. Water and Forton VF-774 are added by weight. Plasticizer is added. Iron oxide pigment is added as a base color. The liquid components and pigment are premixed. The dry components are added to the wet and mixed. The sides and bottom of the container are scraped. Part of the face coat mix is poured into a "hopper" style spray gun. The spray pattern is tested before spraying onto the mold surface. The spray gun applies a consistent layer of face coat on the mold surface. Once applied to the entire surface, the first face coat is lightly brushed smooth. A second face coat layer is applied immediately after brushing. The face coat is allowed to stiffen until the surface loses some of its wet sheen.
Mixing and Applying GFRC Backup Mix (04:03)
A larger high shear mixer is used to process larger volumes of material. Forton VF-774, water and plasticized are added. Iron oxide pigment is added. The mixer is started. Sand is added. Cement is added. The sides of the container are scraped. AR Glass fiber is added. A thin first layer of backup mix is gently applied to the entire surface. A bubble buster is used to work out air bubbles. A second layer of backup mix is applied to the entire surface. The second layer is compacted. A final layer of backup mix is applied up to the full wall height. The final layer is compacted. AR glass scrim is laid onto the wet panel and gently worked into the mix. A small amount of backup mix is applied over the end of the masonry ties. Plastic sheeting is placed over the back of the panel. The plastic prevents excessive moisture loss and maintains heat of hydration to ensure a proper initial cure. The panel is allowed to cure for 12-16 hours. The mold is reset for the second panel. The second panel is produced. The second panel is placed next to the first for additional curing. The third and fourth panels are produced. All panels are allowed to cure for 7 days before staining.
Staining and Sealing the GFRC Panels (08:27)
A water based concrete stain was chosen for this project. An even coating is applied by brush and then allowed to dry. To highlight the wood grain, the stained panels are lightly wet-sanded. A wire brush is used to bring out the details in the deeper textures. Once the panels have dried, a water resistant sealer is applied. The sealer is worked into the surface with a foam pad and roller. The sealer's satin finish further highlights the wood grain. The panels are allowed to cure.
Panel Installation (09:55)
The panels are installed at the house. A cast iron shower pan is installed. The bottom real panel is the first to be installed. Each panel is dry fit in place. A thick bead of construction adhesive is applied to the panel. The panel is lifted into position and pressed firmly in place. Galvanized screws are driven through the masonry ties into the wall. The top real panel is glued and screwed in place. The left side panel is glued and screwed in place. A stud wall is built to support the right side panel. The right side panel is glued and screwed in place. A carbide tipped hole saw is used to bore holes for plumbing fixtures. Brown silicone caulk is used to waterproof joins between panels. The shower door is hung and adjusted. The door rail is mounted directly through the GFRC panel. The water resistant panels dry quickly.
Learn more about GFRC at www.smooth-on.c...
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Adult Supervision Required
Keep Out Of Reach Of Children
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[@terretulsiak]

The craftsmen did a great job and the result looked very cool. I never understand why I go into million dollar homes that all have the same tired granite counter tops and honed showers.

[@Khether0001]

I don't watch even cable TV anymore for the last 3 years or so due growing personal intolerance to adds... This is the ONLY product advertisement I not only watch, but I've subscribed to, even though I'm not even allowed to purchase your products (this is supposed to reflect an insanely big compliment!) ; )

[@robertb7864]

This is a great demo video. Aside from the fact that this is used in a bathroom, it demonstrates how the product is used and can be adapted. A job well done.

[@SeanLumly]

Wow! That is amazing! It is so convincing as reclaimed wood but with the material properties of concrete and without needing to find and purchase distressed wood. This is very cool stuff.

[@everythingyoudwanttoknow]

And no water block under the panels... Mold likes that :)

[@smoothon]

Casting GFRC Concrete to Create Textured Shower Panels - KZbin buff.ly/1zFpaYZ

[@Daffodil956]

Beautiful

[@smoothon]

Thanks for watching, and don't forget to subscribe!

[@ThatGuy-ip3br]

I like your stand for pouring out of buckets. I was a gelcoat sprayer for almost 7 yrs. Poured uncountable mixes from pails and found the only mess came from other workers needing some gel for fillers or repairs. After pulling the little seal under the cap I would always pour with the spout orientated at the 12 o'clock position. You can get the bucket almost to 90° before it comes out. If you pour from a full pail into a mixing cup holding the spout at the bottom a little bit always dribbles out onto the lid. I always knew when somebody was in my booth. I stopped caring after about 5yrs cause I figured it out. You cant fix stupid.

[@pabrad1]

very creative usage of mold materials and the GFRC

[@VariablePenguin]

That's pretty freaking amazing.

[@TheBillyBlack]

Impressive surface guys. The complete lack of waterproofing, and bare plywood substrate made me want to cry though. Constriction glue?!?!? Are you kidding me? Hopefully no one is in there when one of those monsters finally peels off.

[@plasticbaldy]

There were screws as well William.

[@redwolf0083]

i agree, I don't believe this is up to code. Definetly requires a steel mesh with mud.

[@FreddysHamster]

@@redwolf0083 code = tyranny

[@smoothon]

This KZbin video discusses how to make a #concrete shower that looks like wood. Check it out. buff.ly/1ASvE3M buff.ly/1IpeJdX

[@yogeshparakhiya7593]

,, ZX GH

[@JohnLoganMcKee03]

Nice rain room.

[@wileyearly7051]

Nice looking product.

[@maximus7809]

good job

[@kharnakcrux2650]

amazing indeed. Not just texturing, but i've had artistic and decorative ideas. Even with things like silicone decorative linings, 3D textured. I think there's a good market for it.

[@user-xe4fp7ho6r]

اعمالكم قمه في الابدداع

[@roman2011]

Nice!

[@smoothon]

Thanks for watching!

[@confiscator]

Impressive. I'm skeptical as to its time and $ value over sourcing and treating reclaimed wood, but I guess if you had a ton of orders it would make sense.

[@raymondhoffmanjr2634]

great looking stuff quite labor intensive what was the total cost

[@luish.villanueva7216]

not to my woood wall, great idea.

[@wegotlost5269]

I would of uses a latex fortified thinset and not construction glue and I would of used Hardiback board and not plywood in the shower area.

[@chinhvannguyen1685]

Very nice, diferrent of GCR panel vs fiber cement board?

[@laserfalcon]

Caught me off guard when they stopped the mixer

[@taylorlangan6712]

Can it be cleaned like a normal shower? And what is the life expectancy on the water resistant coating? Will it ever need to be recoated?

[@smoothon]

For regular cleaning, abrasives should be avoided, but other traditional non-abrasive cleaners like Clorox, Mr Clean, etc, would be fine. As for maintenance, the sealer would not need to be reapplied, but an annual coating of paste wax would be beneficial…carnauba wax will work.

[@CyberFenix000]

For the plumbing, are there any considerations?

[@deyc3]

I find it better to mix the white Portland cement into the liquids before adding sand. Otherwise we end up with cement clumps.

[@ArtisanTony]

What grade of sand are you using? and you just have to keep mixing until all the clumps are gone :)

[@willy8477]

geweldig

[@plasticbaldy]

What percentage shrinkage is there with GFRC and Forton VF-774 during cure please ?

[@OneWildTurkey]

2:48 - "premixed" ?? just like "predrilled" - sure

[@steventheoschuster1060]

Talk about time consuming.

[@fusic09]

Does anyone know where this mold can be purchased and roughly how much?

[@mohammedjaseim7938]

thankssssssssssssssssssssssssssssssssssss

[@ortafunk]

too Jonesy for Me, first spaces allow for mold and pest to hide and cement absorbs cold like a magnet and will freeze up the Water lines. pressure treated lumber and Polyester and galvanized tin and fiberglass Is the way to go. I use a Ice shelter as a shower room and soon hope to get a Clam Insulated Ice shelter which should be even warmer. cement Is good for a Summer time shower room but Not Winter.

[@u0312717]

I am wondering how you got the nail holes pattern and wood board pattern? (it looks like round nail heads evenly spaced as well as parallel spaced lines starting at 7:30 through the video; you never showed the patterns created and implemented? thanks

[@smoothon]

Hello Sam, Thank you for your interest in our materials. All of the detail that you are seeing came from the original model. In the attached link it will show you how to make a mold, and how the material picks up the detail from the model. kzbin.info/www/bejne/bnnch3aMm7-SnZo

[@u0312717]

O cool, thank you! Sam

[@josephcolangelo9867]

Sam Lorin (

[@matthewfiedler798]

What was the sealer Brand and type used?

[@smoothon]

The sealer is a 4-component product called Imperial i-Tech Countertop Sealer, from Kingdom Products

[@THOMASTHESAILOR]

Beautiful, But, I watched for 10 minutes to see the Young Lady Shower, But, NO ! .. How well does that stuff resist Mold, and Mildew.? Why would they do all that work,? when you can just buy a Plastic universal shower kit, installs in an hour, ready for the Young lady. If She shows up,

[@charmlighter]

waaaaaaaay to much work and would probably cost an arm and a leg for materials .. where as could go to B&Q and buy these exact pannels for £40 each

[@willtaylor8564]

Is the KFC bucket mandatory, or just recommended ;)

[@dalepres1]

Music is too irritating. Shutting this video off.

[@lewandlo]

It must be a bumer to keep clean. Don`t use any comet or powder cleaner on this because it will take off the finish. Can you say a hundred easy payments?? lol

[@Studio-62]

+lewandlo I have a porcelain tile shower and all I ever do is squeegee after the shower and it never gets dirty. It's 4 years old and still pristine, except the grout, which is slightly discoloured but can also be cleaned. I am about to do a concrete shower in my basement. I imagine with all the detail in those panels some stuff can collect in the nooks and crannies. I think if it is rinsed it off after the shower and it's cleaned with a little dish soap and a soft brush every few months it should stay clean. I'm pretty sure it can be re-sealed as well.

[@chuckcassel5417]

lewandlo nn

[@jamesharris9558]

Very easy if you have a water softener. Impossible otherwise

[@frankhoffman3566]

What? Is the world packed with people who think they can make anything into a music video? I was looking for information, not bad, distracting music. .

[@Daffodil956]

Beautiful