Washago coaling plant--step 5

Now we attach the formwork to the base. Keep in mind that you want to be able to remove the forms after the hydrocal has set. So you want an adhesive that is flexible, yet strong enough to hold in place. I used LePage's water-based contact cement for the joints between the balsa and plywood, allowing only about 1/2 hour for the glue to set before joining the pieces.



Attach your formwork in the sequence shown, starting with the picture above. Be sure to keep the forms flush against the lines, to the outside. Squareness is essential. You will note that I cut the outside track and conveyor side forms a little long (which I would not do, if starting over).



Now add three of the inside forms, as shown above. Note that the inside track form is aligned with the 3" x 6" strip between the forms.



Now add the inside conveyor side form, again with the 3" x 6" strip aligned between the forms.



Insert the plug which will create an opening in the main foundation wall to allow passage for coaling plant men in and out of the conveyor room. This piece should be aligned 5'-7" from the right side of the form. Employ adhesive on the bottom face only--not on the surface joints with the forms. NOTE IN THE PICTURE ABOVE THAT I HAVE THIS PIECE ON THE WRONG SIDE!! DO NOT REPEAT MY MISTAKE.



Finally, add the outside conveyor side wall and the formwork is complete. Wrap a number of elastic bands around the formwork to prevent the corners from opening. The hydrocal will exert considerable force against the joints.