Overview – MAS™ Forming Systems
The heart of the MAS™ forming system is the inflatable air-form used to create the dual bisecting arches which form the structural basis for the MAS™ units. All the MAS™ forming systems described below, incorporate the MAS™ air-form and associated shotcreting of the arch areas formed by this air-form. The G1, G2 and G3 MAS™ forming systems require the air-form to be put in place before erecting the Cube Corner Forms. The G4, G5 & G6 MAS™ forming systems are erected first, poured with concrete and then stripped BEFORE the MAS™ air-form is utilized. Thus, by employing the G4, G5 or G6 forming system, the air-form & cube-corner forms have a lower daily utilization rate, allowing for more MAS™ units to be completed per month for any given quantity of form sets.
MAS™ G1 Forming System
The G1 Forming System is the original forming system developed by Southern Utah University. It consists of welded square tubes with a hinge system to allow their collapse and removal once shotcrete is applied and sufficient cure has be obtained. This forming system is no longer supported.
MAS™ G2 Forming System
The G2 Forming System was developed by MAS™ shortly after it’s inception. It consists of an adjustable arch structure made with tubular steel with pins to allow collapse and removal once shotcrete is applied and sufficient cure has be obtained. This forming systems allows for the MAS™ units to be constructed using 100% shotcrete application on all areas of the structure above the foundation/pad. It is also possible to construct without Extruded Polystyrene Foam (EPS), used for insualtion, by employing removable honeycomb polycarbonite panels. The optional MAS™ eave forming system can be employed with the G2 forming system. However, it is recommended to use the G3, G4 or G5 system when eaves are desired.
MAS™ G3 Forming System
The G3 Forming System was developed by MAS™ in 2013. It consists of the same basic G2 forming system however the cube roofing system is formed using a LiteDeck® system. The LiteDeck® system is composed of Extruded Polystyrene Foam (EPS) that provides for a system of 5 beams to be formed homogeneously with the concrete roofing deck. Eaves are simple to incorporate as the LiteDeck® sections can be extended to created the desired eave overhang up to 24 inches.
MAS™ G4 Forming System (*MOST POPULAR*)
The G4 Forming System was developed by MAS™ in 2013 and is the recommended forming system for projects that require insulation. The G4 forming system is an entirely new forming system that uses none of the components of the G1 or G2 forming systems. It consists of readily available standard or decorative concrete forms which are used to form the cube corner walls. The cube corner walls can be formed all at once, in pairs, or individually to decrease the cost of forming. Extruded Polystyrene Foam (EPS) can be inserted at thicknesses up to 4″ inside the concrete forms to provide for insulation. Texture plates can also be employed to “mold in” faux features such as bricks, rock, etc. on the exterior of the walls. These concrete cube corner forms are filled with poured concrete. Once sufficient cure has been obtained (typically overnight) the forms are stripped and a LiteDeck® roof forming system is employed.
The LiteDeck® system is composed of Extruded Polystyrene Foam (EPS) that provides for a system of 5 beams to be formed homogeneously with the concrete roofing deck. Eaves are simple to incorporate as the LiteDeck® sections can be extended to created the desired eave overhang up to 24 inches. The LiteDeck® system is ordered in kits that are custom cut at the factory to achieve the desired eave overhang distance as well as the proper arc cut to interface to the bisecting arch system that is created with the MAS™ air-form and is a key structural component of the MAS™ units.
The LiteDeck® system is sacrificial in that it remains in place to provide insulation. Another KEY feature of the MAS™ G4 forming system is the ability to have a taller height on the cube corner walls and/or a lower cube corner roof “Hip Rafter” intersection point on the bisecting arch structure. This allows for more or less of the “top hat” dome architectural feature to be visible.
MAS™ G5 Forming System
The G5 Forming System is currently under development and is expected to be available in the 2nd quarter of 2014. The G5 forming system will be employed when NO insulation is desired. The G5 forming system is the same as the G4 forming system, except that the LiteDeck® roofing system is replaced by a removable/reusable aluminum cube roof forming system.
MAS™ G6 Forming System
The G6 Forming System is currently under development and is expected to be available in the 4th quarter of 2014. The G6 forming system is a precast system. The G6 Forming System will employ specially configured Extruded Polystyrene Foam (EPS) sandwiched between thin layers of concrete to create MASTratum™ panels.
The MASTratum™ panels are lifted into place by a small lift, to form the cube corner walls and cube corner roofs. The advantages of the G6 forming system is the ability to mass produce the MASTratum™ panels in a weather protected environment, as well as provide for a controlled and accelerated curing process. The MASTratum™ panels will also have the same molding/texture capability as the G4 & G5 system, with the added ability to incorporate this molding/texture capability in the cube roofing system.
Summary
Please consult with your MAS Distributor to determine which MAS™ forming system is right for YOUR project. NO matter which MAS™ forming system you employee, the basic visual and structural attributes of the MAS™ units are the same. The end results is the least expensive, strongest, longest lasting, and quickest to build structure in the world.