Column Form Technology

The Problem

Rotten wooden posts are not only difficult and expensive to maintain, they often result in structural issues and even failure if not replaced promtly. In addition to the expense and maintenance issues, they are a safe haven for bugs, termites, beetles and mold.

Typical wooden post applications provide a very “Track Home” style and limited options.

The process of stripping, painting, repairing or replacing your posts is very time consuming and often takes several days. The resulting noise and mess produced by the repair/replacement is a nuisance at the very least. Maintenance costs for the above typically run in the thousands of dollars and are ongoing.

The longer the rotting or insect problem is left unchecked, the more opportunity for these issues to migrate into and infest the patio structure itself.

From a design viewpoint, your patio posts should be considered more than just vertical supports which hold up the structure. Rather, they should be viewed as decorative elements that will contribute to your backyard environment for years to come.

The Solution

Few materials are as versatile and maintenance free as Concrete. The lure and durability of concrete goes without saying. Concrete as a medium complements most other products such as wood, stone, vinyl, plaster and steel. In addition, concrete can be internally colored, painted, dyed or stained.

The Column Cast™ offers a revolutionary new process, that yields all the benefits of a true “cast in place” concrete post/column, utilizing a highly efficient design which results is unparalleled labor savings while maintaining a clean work site. There is no need for costly power equipment typically used in job-built applications; no table saws, no skill saws, no planers, no hammers, no screw guns, no sawdust, no extension cords, no accidents, no blow-outs, no mess and no noise.

Unlike coated foam or fiberglass, your posts will boast the beauty and durability of a true structural concrete column. Complete with a galvanized steel inner sleeve, and seismic connections to meet code requirements. There are several shapes and styles to choose from, and combinations can be used to create your own unique style. Termites will no longer have a place to enter, multiply and destroy your Patio. Your beautiful growing vines and folage will no longer have to be destroyed every time your wooden posts are re-painted or re-placed.

In addition to all the other benefits, our process results in very little inconvenience to you. Your post forms are pre-made and delivered complete and ready to pour. Your contractor will typically set the posts in the morning, mix and pour by noon of the same day, take lunch, then strip the forms in the afternoon. The work area will remain free of unsightly debris, the impact to your yard and surrounding follaige is minimal, and the whole process typically takes only one day!

Call today to schedule an appointment so you can begin enjoying your maintenance free patio posts, instead of worrying about them!

The Market (Residential)

The initial launch of the Column Cast System&trade will focus on replacement of rotten wood patio and fence posts. This is obviously a huge market being that nearly every home has a front or rear patio, entry columns, a pergola, gazebo or all of the above. Most of them were initially made of wood, and most of them have already begun rotting and are in need of repair or replacement.

In addition, Architects are under increasing pressure to introduce additional design elements into their retrofit and new creations including parking structures, building entries, open hallways etc. While The Column Cast System™ is unsurpassed in replacement applications, it is also invaluable as a new construction system where a decorative result is required.

The Market (Commercial)

In both new construction, and especially retrofit applications including parking structures, stadiums, building entries, malls, basements, open hallways, corridors etc., the Column Cast System™ is unsurpassed. Design options are virtually limitless, and the efficiency of the Column Cast System™ is realized wherever a decorative result is required.

The Product

The Column Cast™ is a re-useable forming system that encapsulates a styrofoam shape to provide support while the concrete is poured and curing.

Our System includes:*

• CFT Column Cast Jacket
• CFT Detailed and Coated Foam Inserts
• CFT Decorative Post & Column Mix
• CFT Form Release
• CFT Pour Chute
• CFT Replacement Accessories
• CFT Plumb Jig
• CFT Pencils
• CFT Accelator
• CFT Pigment Packs

* available at your local construction supply store summer 2009

Check out our improved latch design:

PSF Rating, Safety Factor, and other details:

This system is rated at 2,250 lbs PSF with a 2:1 safety factor. Columns can be poured up to a 15’ full liquid head with a 14” diameter jacket.

Once the concrete has sufficiently cured, the Column Cast™ may be relocated to support another column form. The styrofoam will remain inplace from the first pour until curing is sufficient and the detail is ready to strip from the concrete.

This process will greatly reduce the set-up, pour and strip time, as well as eliminate the need to purchase and build single-use cardboard or wood forms. There are no power tools required for this operation.

With the Column Cast™ System, available column shapes are unlimited. With the proper release agent the styrofoam form can also be re-used.

Other systems only offer round or square shapes, and are very expensive single use systems. Column Cast™ jackets are rolled into a tight bundle during transport and storage. Other systems are very large and cumbersome to transport and store.

The Competition

	Column Cast™	Cardboard Tubes	Job Built
Build Time	1min 30sec	15min 0sec	3hrs 16min
Material Cost p/ft	$8-10	$12-15 w/inserts	$6-10
Labor Cost p/ft	$1.25	$6.50	$18.75
Multiple Use	yes	no	yes
Retrofit w/ seismic connection	yes	no	yes
Form Around Existing	yes	no	yes
Erect w/o Power Tools	yes	yes	no
Styles/Shapes	unlimited	round/square	limited
Accident Free	yes	yes	no
Blow-out Free	yes	yes	no
Waterproof	yes	no	no
Engineered Pour Rate	yes	yes	no
Clean Work Site	yes	yes	no
Minimal Storage Space	yes	no	no
Minimal Inventory Space	yes	no	no
Unskilled labor	yes	yes	no

Video from World of Concrete (WOC '09)

The Reviews