Method for casting concrete members

A method of forming a concrete member is provided which includes the following steps: in a mold structure having a plurality of lateral walls defining a cavity, introducing a liquid into the cavity to a predetermined level above a drainage conduit which leads to a weir having an upper edge which is higher than the liquid level; forming a layer of fusible material on the surface of the liquid, the fusible material being of lesser density than the liquid and having a melting point which is above the temperature of the liquid, by introducing molten fusible material into the cavity until the liquid begins to flow over the weir; after the fusible material has solidified, introducing a concrete mix into the cavity onto the fusible material; when the concrete mix is at least partially cured, establishing a flow of warm liquid into the cavity below the fusible material and over the weir, the warm liquid having a temperature above the melting point of the fusible material so that the fusible material is melted; draining the molten fusible material from the cavity; and draining the liquid from the cavity.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to a method and apparatus for 
casting concrete members, and more particularly to a method and apparatus 
for casting multiple-slab, hollow-core concrete members having structural 
tying members extending between the slabs. 
2. Discussion of the Prior Art 
In casting some concrete members, it is advantageous to use molten wax 
cooled to a solid state as the bottom of the mold or form. For example, 
concrete panels having embedded decorative or functional elements in one 
surface can be advantageously formed using a wax mold bottom, as shown in 
Terrio U.S. Pat. No. 3,331,175. However, until recent years, those in the 
art had not been able to develop techniques which permitted easy removal 
of all of the wax from the cast slab and casting bed after the concrete 
had cured. One of the first successful attempts is disclosed in U.S. Pat. 
No. 3,608,051. This patent teaches a method in which hot water or steam is 
directed around the mold members and into direct contact with exposed 
peripheral edges of the wax layer to melt the wax and thus remove it from 
the slab and mold. This was an improvement over earlier proposals in that 
the wax is substantially completely removed and can be separated from the 
hot water for reuse. 
A variation of this technique is disclosed in U.S. Pat. No. 3,689,626 for 
casting multiple-slab, hollow-core concrete panels. In this method, wax is 
used to cast concrete members having two or more spaced apart slabs with 
structural steel tying members joining them together. In the method of 
this patent, a first layer of wet concrete is poured into a mold formed 
within an enclosed water-tight tank. The concrete is poured onto a mold 
bottom formed by a layer of solidified wax at least partially supported by 
a pool of water below the wax layer. Upwardly extending tying members are 
embedded in the wet concrete and a second layer of water is introduced 
into the tank. Molten wax is introduced into the tank to cover the water 
and to form, when solidified, a second mold bottom spaced above the first 
slab. Cold water is circulated below the wax layer to cool and solidify 
the wax to form the second mold bottom. The height of the wax layer is 
such that the tying members extend above. When the wax has solidified, a 
second layer of wet concrete is poured onto the suspended wax layer to 
cover the upper ends of the tying members and form the second slab. When 
this upper layer of concrete has set sufficiently to be self-sustaining, 
the cold water in the tank is displaced by hot water, and hot water is 
circulated through the tank until all of the wax is melted and removed 
through an appropriate tube. 
The method just described is a great improvement over prior methods of 
forming multiple slab hollow panels. The system depends, however, on the 
construction of a large water-tight tank with suitable casting deck 
forming the bottom of the tank or construction within the tank. All form 
work for the concrete structures to be made therein are independent of the 
tank and deck structure. Thus, any size or shape of panel could be formed 
so long as it did not exceed the area limits of the casting deck. When the 
product to be made required the embedding of decorative materials, a 
reticulated structure was placed within the tank to serve as a casting 
deck. Since the perimeter forms for containing concrete were inside the 
tank perimeter, it was necessary to use a cover over the entire surface of 
the tank during the curing operations in order to prevent undue heat loss. 
While such method provides great flexibility in terms of the variety of 
products which can be produced, the system does not lend itself to 
portability. The whole system is larger and more cumbersome than required 
to make quantities of products having predetermined dimensions. 
Hence, it is a primary object of the present invention to provide a method, 
apparatus, and system for casting concrete members which are improvements 
over those disclosed in U.S. Pat. No. 3,689,626, and which effectively and 
reliably overcome the drawbacks and limitations of the prior art 
proposals. More specifically, the present invention has as its objects one 
or more of the following taken individually or in combination. 
(1) To provide a self-contained, portable system for casting concrete 
members; 
(2) The provision of self-contained wax and water distribution channels and 
drainage channels in a system for casting concrete members; 
(3) To provide means for simply and accurately controlling water level in a 
concrete casting system for casting multiple slab castings with structural 
members extending therebetween; 
(4) The development of valve means which expedites removal of wax from a 
concrete casting mold; 
(5) To provide a method and system for casting multiple-slab, hollow-core 
concrete panels on any flat bed without the need for a special water-tight 
tank in which to place the mold; 
(6) To provide a method and system for casting multiple-layer, hollow-core 
concrete panels which can be utilized efficiently at a job site; 
(7) To provide a method and system for casting multiple-layer concrete 
panels in which the perimeter forms for the finished product combine with 
the deck on which they are placed to form the container necessary for 
containment of liquids required in the process; 
(8) To provide a method and system for casting multiple-layer concrete 
panels without the need for a structural cover during curing operations; 
and 
(9) To develop a casting system which is versatile in that it can be easily 
modified to cast panels of a wide variety of dimensions. 
SUMMARY OF THE INVENTION 
This invention responds to the problems presented in the prior art by 
providing a method of forming a concrete member which includes the 
following steps: (1) in a mold structure having a plurality of lateral 
walls defining a cavity, introducing a liquid into the cavity to a 
predetermined level above a drainage conduit which leads to a weir having 
an upper edge which is higher than the liquid level; (2) forming a layer 
of fusible material on the surface of the liquid, the fusible material 
being of lesser density than the liquid and having a melting point which 
is above the temperature of the liquid, by introducing molten fusible 
material into the cavity until the liquid begins to flow over the weir, 
whereby the upper level of the fusible material is determined by the 
height of the weir; (3) after the fusible material has solidified, 
introducing a concrete mix into the cavity onto the fusible material; (4) 
when the concrete mix is at least partially cured, establishing a flow of 
warm liquid into the cavity below the fusible material and over the weir, 
the warm liquid having a temperature above the melting point of the 
fusible material so that the fusible material is melted; (5) draining the 
molten fusible material from the cavity; and (6) draining the liquid from 
the cavity. 
The invention thus provides means for accurately controlling the water and 
wax levels in a concrete casting system which is simple yet effective. The 
invention also eliminates the need for a water-tight tank. 
Another way to define the invention is as a mold structure for casting a 
concrete member. So defined, the structure includes the following 
components: (1) a centrally disposed cavity defined by a plurality of 
lateral walls; (1) liquid distribution means in one of the walls for 
distributing liquid into the cavity; (2) molten fusible material 
distribution means in one of the walls for distributing molten fusible 
material into the cavity; and (3) drainage means in another of the walls 
for draining liquid and molten fusible material from the cavity, the 
drainage means comprising a drainage conduit in the wall leading to weir 
means for controlling the liquid level in the cavity, and dam means 
disposed in the wall above the drainage conduit, the dam means being 
operable to control the drainage of molten fusible material from the 
cavity. Defined thusly, the invention provides a self-contained, portable 
casting system having wax and water distribution channels and drainage 
channels which are built into the walls of the mold structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Construction of the Casting Bed 
A suitable casting bed 10 for making large scale concrete panels, such as 
those used in building construction, is shown in plan view in FIGS. 1 and 
5. A sump 12 is indicated partially in phantom below one corner of casting 
bed 10. The periphery of casting bed 10 is defined by a movable side 
channel 14, a movable end channel 16, a fixed side channel 18, and a fixed 
end channel 20. 
Movable side channel 14 is best depicted in FIGS. 2 and 4 and includes 
means for controlling the drainage of a fusible material and a liquid from 
casting bed 10. The fusible material normally used with the invention is 
petroleum wax, and water is the liquid normally used. Therefore, this 
description will deal only with these materials. It should be appreciated, 
however, that other conventional materials may alternatively be utilized. 
Movable side channel 14 rests upon a casting bed top plate 22 which, 
together with side and end channels 16, 18, and 20, defines a casting bed 
cavity 23. Movable side channel 14 is adapted to be moved inwardly and 
outwardly through the use of a plurality of evenly spaced jack screws 24, 
thereby permitting cavity 23 to be opened at the corners for drainage of 
water from the cavity and to facilitate removal of the concrete member. 
Each of the jack screws 24 is threaded into a jack screw mounting plate 26 
which is affixed to casting bed top plate 22. Jack screws 24 are affixed 
at one end to an L-shaped trough member 31 of movable side channel 14 by a 
pair of lock nuts 28 disposed on each side of a jack screw mounting 
channel 30. The end of each of the jack screws 24 which is remote from 
trough member 31 includes an operating lever 32 to oermit jack screws 24 
to be threaded inwardly and outwardly with respect to jack screw mounting 
plates 26, thereby sliding movable side channel 14 along casting bed top 
plate 22 in an inwardly or outwardly direction. 
Movable side channel 14 includes a weir chamber 34 and a trough 36 with a 
vertically extending division plate 38 disposed therebetween. A vertically 
adjustable weir 40 is mounted to division plate 38 by a plurality of bolts 
42, one of which extends through each of a plurality of weir mounting 
slots 44. This configuration permits weir 40 to be adjusted upwardly and 
downwardly. 
Movable side channel 14 also includes a channel member 46 which extends the 
length of the side channel. Upper and lower screeding channels 48 and 50 
are mounted to the inner side of channel member 46 and, together with the 
channel member, define the inner periphery of movable side channel 14. 
A plurality of water drainage ports 52 are evenly spaced along the length 
of channel member 46 to drain water from cavity 23 and into weir chamber 
34. Wax drainage slots 54 are also included along the length of channel 
member 46 to drain wax from cavity 23 and into weir chamber 34. A 
plurality of anti-shear tongues 56 extend inwardly from channel member 46 
immediately below wax drainage slots 54 to help support the perimeter of 
the wax layer. 
An L-shaoed wax dam 58 is mounted to the outer surface of channel member 46 
by a plurality of evenly spaced support clips 60 which extend between the 
upper horizontal and vertical portions of channel member 46. With wax dam 
58 in its lowered position depicted in FIG. 4 and in solid lines in FIG. 
2, wax drainage slots 54 are covered. With wax dam 58 in its raised 
position depicted in phantom in FIG. 2, wax drainage slots 54 are 
uncovered to permit wax to flow out of cavity 23. 
Wax dam 58 is affixed in its lowered position by a pluralitv of wedges 62, 
one of which is wedged into place between the wax dam and the vertical 
portion of each of the support clips 60 to positively hold wax dam 58 
against channel member 46 and prevent leakage of wax out of casting bed 
10. Wax dam 58 is fixed in its raised position by positioning wedges 62 
between the wax dam and the vertical portion of each of the support clips 
60. Keeper chains 64 loosely attached wedges 62 to movable side channel 14 
while permitting the wedges to be freely manipulated by the operator. 
Keeper chains 64 have not been shown in FIG. 2 for simplification. 
In an alternative embodiment, the water drainage holes and wax drainage 
slots are combined into a single set of openings of enlarged height with 
the wax dam being disposed, in its lowered position, to cover the upper 
portion of the openings. This upper portion is where the wax would 
otherwise flow through the channel member. This alternative embodiment is 
not the preferred mode, however, so has not been depicted. 
In the depicted embodiment, stiffening bars 66 extend between channel 
member 46 and trough member 31 every few feet or so to tie the trough and 
weir chamber portions of movable side channel 14 together. 
A weir chamber drain line (not shown in FIG. 2) is provided at one end of 
weir chamber 34 to permit the weir chamber to be drained directly into 
sump 12. A weir chamber drain valve (not shown in FIG. 2), which is 
normally closed, controls the flow through the weir chamber drain line. 
Similarly, a weir overflow conduit (not shown in FIG. 2) is provided at 
one end of trough 36. It is normally in the form of a simple opening in 
the floor of the trough 36 and casting bed top plate 22 above sump 12 so 
that whatever flows over weir 40 will drain into the sump. 
Movable end channel 16 includes a channel member 68 with a stiffening 
member 70 extending substantially its entire length. Channel member 68 is 
substantially C-shaped in cross section for its entire length except for 
the end which extends beyond movable side channel 14 where, as shown in 
FIG. 4, it is L-shaped in cross section. A joint 76 is provided between 
movable end channel 16 and movable side channel 14 and is typically sealed 
through the use of mastic or caulking or the like. 
Channel member 68 is movable through the use of a pair of spaced jack 
screws 72 which are mounted to channel member 68 and casting bed top plate 
22 as described above with respect to jack screw 24; that is, a jack screw 
mounting plate 74 is internally threaded to receive each of the jack 
screws so that when the operator rotates jack screw handles 75, channel 
member 68 shifts inwardly and outwardly along the surface of casting bed 
top plate 22. As mentioned above, this permits the corners of casting bed 
10 to be opened to drain cavity 23 and to permit removal of the cast 
concrete member. 
Fixed side channel 18 is best depicted in FIG. 2. It is substantially 
rectangular in cross section and comprises a wax supply header 78, a water 
supply header 80, and upper and lower screeding channels 82 and 84, 
respectively. Fixed side channel 18 is affixed to casting bed top plate 22 
as by welding or other permanent means. Wax and water are provided to wax 
supply header 78 and water supply header 80 by conventional conduits and 
suitable couplings, which have not been shown in FIG. 2, but are 
schematically depicted in FIG. 5. A plurality of evenly spaced water 
supply ports 86 are provided along the length of water supply header 80, 
substantially in vertical alignment with water drainage ports 52 in 
movable side channel 14, thus ensuring that whenever the water level in 
water supply header 80 extends as high as water supply ports 86, water 
will flow into cavity 23 at an even rate. A plurality of evenly spaced wax 
supply ports 88 are similarly provided along the length of wax supply 
header 78 immediately below the lower edge of upper screeding channel 82, 
thus in substantial vertical alignment with wax drainage slots 54 in 
movable side channel 14. A plurality of antishear tongues 89 are evenly 
spaced along the length of wax supply header 78 immediately below the 
level of wax supply ports 88 to provide support for the wax layer as 
described above with respect to antishear tongues 52. Because wax supply 
ports 88 are disposed along the lower portion of wax supply header 78, 
whenever any substantial amount of molten wax is fed into the wax supply 
header, that wax will flow at an even rate through wax supply ports 88 and 
into cavity 23. 
Fixed end channel 20 is shown in cross section in FIG. 3. It includes a 
substantially C-shaped channel member 90 which is affixed, such as by 
welding, to casting bed top plate 22. A water drain line 92 extends 
through channel member 90 to permit water to be drained from cavity 23. A 
water drain valve 94 is provided in water drain line 92 adjacent channel 
member 90 to control the flow of water therethrough. This valve is 
typically a quick opening plate-type valve to facilitate rapid drainage. 
Water drain line 92 drains water downwardly from cavity 23 into sump 12 
which is disposed below and adjacent one corner of casting bed top plate 
22. Thus, while water drainage ports 52 combine with weir 40 to control 
the level of water in cavity 23, water drain line 92 is utilized to remove 
substantially all the water from the cavity at aporopriate times during 
casting operations. 
Sump 12 includes overflow means which permits excess water to flow out of 
the sump and out of the system through an overflow line 100. A wax 
holdback dam 102 and an overflow weir 104 combine to minimize the 
possibility of wax being lost from the system through overflow line 100. 
Return line 106 extends into sump 12 adjacent the lower portion thereof to 
provide water and wax to a system pump 108. 
Water and Wax Preparation System 
The water and wax preparation system 110 depicted in FIG. 5 will now be 
described. The major components of the system 110 are the aforementioned 
system pump 108, a three-way valve 112, a water and wax separator tank 
114, a water heater 116, and a hot water supply tank 118. 
System pump 108 is typically a positive displacement, air driven pump, with 
air being provided through an air supply line 120. Electrically driven 
centrifugal pumps may alternatively be used. Pump discharge and inlet 
valves 122 and 124, respectively, are provided at the discharge and inlet 
ends of pump 108. Pump 108 discharges through a separator tank inlet line 
126 into separator tank 114. Separator tank 114 includes a central baffle 
128 and serves as a settling tank to vertically separate the molten wax 
from the water. 
A water recirculation valve 130 is provided in a water recirculation line 
132 to permit water to be recirculated back into sump 12. Water 
recirculation valve 130 is normally closed but is opened at various stages 
of casting operations, as described further hereinbelow. A drain valve 134 
is provided in a drain line leading from water recirculation line 132 to 
permit water to be drained from system 110 at this point. 
The water which has collected in the lower portion of separator tank 114 is 
directed into water heater 116 via water heater inlet valve 136 and water 
heater inlet line 138. A drain valve 140 is also provided off of water 
heater inlet line 138 to permit the system 110 to be drained at this point 
as well. Water heater 116 is normally a conventional gas-fired water 
heater but may alternatively be electric. It typically includes a 
plurality of turns of tubing as schematically depicted in FIG. 5. 
Depending upon the position of the various valves in system 110, the hot 
water which passes from water heater 116 will either be directed through a 
hot water line 142 and a hot water valve 145 toward casting bed 10, or 
through a supply tank inlet line 144 to hot water storage and supply tank 
118 positioned above wax separator tank 114. Hot water passes from hot 
water supply tank 118 through either a hot water supply line 146 to 
three-way valve 112, or through a supply tank drain line 148 and valve 150 
back to separator tank 114. Hot water supply tank 118 is vented at 152 to 
ensure appropriate drainage from the tank. 
Molten wax which has risen to the top of separator tank 114 is directed to 
wax supply header 78 in casting bed 10 through hot wax line 154 and wax 
supply valve 156. To permit separator tank 114 to be vented without losing 
any wax from the system, first and second separator tank vent valves 158 
and 160 are provided in a separator vent line 162 which discharges into 
sump 12. In order to maintain the wax in separator tank vent line 162 in a 
molten state, a hot water tracer line 164 is provided in close proximity 
to the separator tank vent line. Hot water tracer line 164 is typically 
constructed of copper tubing and for this reason has been indicated with 
dashed lines in FIG. 5. Hot water is provided to tracer line 164 from hot 
water line 142 via hot water tracer valve 166 and discharges into hot 
water supply tank 118. A water hose 168 also takes suction from hot water 
line 142 through water hose valve 170 at this point, for use in washing 
out residual wax and other debris from casting bed 10 when necessary. 
In order to permit wax supply header 78 to be preheated before molten wax 
begins to flow into it, a wax header heating valve 172 is provided to 
direct hot water from hot water line 142 into hot wax line 154 immediately 
downstream of wax supply valve 156. This minimizes the possibility of the 
molten wax solidifying upon contacting otherwise cool surfaces of wax 
supply header. 
A cold water supply valve 174 is provided in a cold water line 176 to 
supply cold water to casting bed 10 through a water inlet line 178. Water 
inlet line 178, which includes a water inlet valve 180, therefore is 
adapted to receive either hot water from hot water line 142 or cold water 
from cold water line 176 and to convey this water into casting bed 10 via 
water supply header 80. 
As mentioned above, weir chamber drain valve 182 in weir chamber drain line 
184 is provided between one end of weir chamber 34 and sump 12 to permit 
the weir chamber to be drained into the sump. This line and valve only 
appear in FIG. 5. Weir overflow conduit 185 is schematically depicted in 
FIG. 5, although, as mentioned above, it actually is in the form of an 
opening in the floor of one end of trough 36, thereby permitting drainage 
into sump 12. 
Operation of the Depicted Embodiment 
To inventory the system with water and wax for casting, all of the valves 
in system 110 should be closed with the exception of pump discharge and 
inlet valves 122 and 124 and water heater inlet valve 136. Hot water 
supply tank 118 is filled with an appropriate amount of water through vent 
152 or other filling means (not shown). Three-way valve 112 is positioned 
as shown in FIG. 5 and pump 108 is started. This pumps water through 
separator tank 114, water heater 116, hot water supply tank 118, and 
three-way valve 112, thereby short circuiting casting bed 10. Water heater 
116 is then energized so that the circulating water is gradually heated. 
When the water temperature reaches approximately 160.degree. F., hot water 
valve 145 and water inlet valve 180 are opened and three-way valve 112 is 
rotated 90.degree. in a counterclockwise direction so that the hot water 
is circulated through casting bed 10. Supply tank drain valve 148 and 
water recirculation valve 130 should be opened until circulation is 
established through pump 108, and then they may be reclosed. 
Once a flow of hot water through the system is established, wax chunks (not 
shown) are deposited in cavity 23 of the casting bed. The circulating hot 
water causes the wax chunks to gradually melt, thereby forming a layer of 
molten wax on top of the hot water accumulated in cavity 23. When a 
substantial portion of the wax has melted, wax dam 58 is moved to its 
raised position, thereby uncovering wax drainage slots 54. This permits 
the now molten wax along with some water to flow into weir chamber 34 and 
to overflow weir 40 into trough 36 and subsequently into sump 12 via weir 
overflow conduit 185. Return line 106 then directs this mixture of molten 
wax and water into pump 108 which pumps the mixture into separator tank 
114. 
Separator tank 114 separates the water from the wax by permitting the water 
to settle downwardly while the molten wax rises upwardly. Since only water 
is withdrawn from separator tank 114 through water heater inlet line 138 
near the bottom of the tank, molten wax will begin to accumulate in the 
upper portion of separator tank 114. 
When a substantial amount of molten wax has accumulated in separator tank 
114, first and second separator tank vent valves 158 and 160 are opened to 
vent separator tank 114 into sump 12. Once wax begins to flow through 
separator tank vent line 162, second separator tank vent valve 160 may be 
closed. First separator tank vent valve 158 may also be closed, but it is 
typically left open since the closing of valve 160 stops the flow of wax 
through separator tank vent line 162. First separator tank vent valve 160 
is periodically reopened to vent separator tank 114. To maintain the wax 
in separator tank vent line 162 in a liquid state between venting 
operations, hot water tracer valve 166 should be periodically opened to 
direct hot water through hot water tracer line 164 which, as mentioned 
above, is in close proximity to separator tank vent line 162. 
Once the wax chunks have been entirely melted, pump 108 is shut down, hot 
water valve 145 is closed and water drain valve 94 is opened to drain the 
hot water and any remaining wax out of cavity 23 and into sump 12. The 
drainage of casting bed 10 is completed by opening a corner of the casting 
bed. This is done by displacing movable side channel 14 or movable end 
channel 16, or both, outwardly using jack screws 24 and 72. 
When all of the water is drained from casting bed 10 and pumped back into 
the storage tank 118, the preliminary inventory of the system is complete 
and will not have to be repeated in normal use. The casting bed is now 
ready for use. 
Casting Operations 
The casting operations for forming a two-layer, hollow-core concrete panel 
will be described, since the illustrated casting bed is adapted for 
forming such a panel. However, the same principles and methods will also 
apply in forming panels with three or more spaced layers using a modified 
casting bed with additional screeding channels, headers, weirs, and dams, 
as required, above those described. 
The movable side and end channels 14 and 16 are moved inwardly until the 
corners of casting bed 10 are closed. The closed corners of casting bed 10 
are sealed, typically, with mastic unless other sealing means is provided. 
If desired, casting bed top plate 22 and the inwardly facing portions of 
side and end channels 14, 16, 18, and 20 are sprayed with suitable mold 
release agents. 
When casting bed 10 is ready, wet concrete is poured into cavity 23 until 
its upper level is even with the top surfaces of lower screeding channels 
50 and 84, to form the first layer of panel. This concrete layer is shown 
in FIG. 6 at 186, with its upper level at 188. Lower portions of 
appropriate structural support members, such as the the steel truss shown 
at 190, are embedded in the wet concrete so that their upper extremities 
extend well above the lower limits of upper screeding channels 48, 82. For 
structural strength in all directions, additional trusses (not shown) are 
embedded at right angles to trusses 190 to form a grid of such trusses. 
Cold water valve 174 is then opened to direct cold water through cold water 
line 176 and water inlet line 178, into water supply header 80. It is 
normally desirable that the cold water be admitted slowly at first until 
the entire surface of concrete mix 186 is covered so as to prevent 
scouring such surface. However, such scouring will be largely prevented by 
upper surfaces of lower screeding channels 50, 84, which act as splash 
boards for receiving the initial cascade of water. With the concrete 
submerged, the water 193 may be rapidly raised to the level indicated at 
192 in FIG. 6, which is slightly below the upoer edge of weir 40. Wax dam 
58 is then shifted to its lowered position, concealing wax drainage slots 
54. Wedges 62 are jammed in place between wax dam 58 and the vertical 
extension of support clips 60 to prevent any leakage through wax drainage 
slots 54. 
Supply tank drain valve 148 is opened to exert hot water supply tank head 
pressure on separator tank 114. Cold water supply valve 174 and water 
inlet valve 180 are closed, and hot water valve 145 and wax header heating 
valve 172 are ooened so that hot water is gravitated into casting bed 10 
through wax supply header 78, thus preheating wax supply header 78. when 
the water level in cavity 23 has risen approximately one-half inch, hot 
water valve 145 and wax header heating valve 172 are reclosed. 
Wax supply valve 156 is opened, permitting molten wax 194 to flow through 
hot wax line 154, wax supply header 78 and wax supply ports 88, into 
cavity 23. When weir 40 begins to overflow with water, wax supply valve 
156 is closed. At this time, the upper level of wax 194 will he at level 
196, substantially coinciding with the lower edges of upper screeding 
channels 48 and 82. The thickness of wax layer 194 may be increased or 
decreased by providing lower or higher water levels, respectively, prior 
to the introduction of the wax into cavity 23. 
After wax supply valve 156 is closed, supply tank drain valve 148 is closed 
and three-way valve 112 is rotated 90.degree. clockwise to the position 
shown in FIG. 5. Pump 108 is started, causing water to be circulated 
through separator tank 114, water heater 116, hot water supply tank 118, 
and three-way valve 112. This circulation of the water through water 
heater 116 restores the temperature of the water to approximately 
160.degree.. 
Cold water supply valve 174 and water inlet valve 180 are opened to 
establish a flow of cold water through water inlet line 178, water supply 
header 80, water supply ports 86, under the layer of wax 194 in cavity 23, 
through water drainage ports 52 and weir chamber 34, over weir 40, into 
trough 36 and finally into sump 12 via weir overflow conduit 185. This 
circulation of cold water solidifies wax layer 194 and raises the layer 
slightly above the lower edges of upper screeding channels 48 and 82. 
Because pump 108 is not drawing water from sump 12, this cold water will 
flow over overflow weir 104 in sump 12 and will pass out of the system 
through sump overflow line 100 to an appropriate drain. In the event the 
system is being used in an area where water is scarce and/or expensive, 
this water may be recycled for subsequent use. 
The flow of cold water 193 under wax layer 194 is continued until wax 194 
has solidified to a consistency which is sufficient to support a concrete 
pour. By this time the wax layer 194 will have shrunk to the level 
indicated at 196, which coincides with the bottom edges of upper screeding 
channels 48 and 82. Cold water circulation is continued while a layer of 
concrete 198 is ooured onto wax layer 194. This circulation continues 
until the concrete 198 has established some preset. 
Once the second layer of concrete 198 has preset sufficiently to be 
supported by structural support member 190, cold water supply valve 174 is 
closed, and water drain valve 94 is opened to permit the water in cavity 
23 to drain through water drain line 92 and into sump 12. When 
substantially all of the water has drained from cavity 23, water drain 
valve 94 is closed, and hot water supply valve 146 is opened to restore 
the flow of water under wax layer 194 and over weir 40. At this point, 
three-way valve 112 is rotated 90.degree. in a counterclockwise direction 
to establish circulation of hot water through system 110. 
As soon as wax dam 58 has warmed sufficiently to be free, the wax dam is 
moved to its raised position, thereby opening wax drainage slots 54 to 
permit the melting wax to flow through the wax drainage slots, into weir 
chamber 34, over weir 40 into trough 36 and sump 12. When substantially 
all of the wax has melted, weir chamber drain valve 182 is opened, 
permitting water and wax to flow through weir chamber drain line 184 and 
into sump 12. This drops the level of water in cavity 23 below weir 40 and 
in effect makes water drainage ports 52 another fixed weir. This will 
cause all of the wax to be passed into sump 12 and, via return line 106, 
pump 108, and separator tank inlet line 126 to separator tank 114. When 
the water is at this low level, hot water should be flushed through wax 
supply header 78 hy opening wax header heating valve 172 to clear any 
residual wax from the wax supply header. 
When it appears that all of the wax has been removed, water drain valve 182 
is closed, thus restoring the flow of hot water over weir 40. This 
circulation of hot water under the second layer of concrete 198 
accelerates the curing time of the concrete. When curing is complete, hot 
water valve 145 is closed, and water drain valve 94 is opened to drain the 
hot water into sump 12. When sump 12 is nearly empty, three-way valve 112 
should be rotated 90.degree. in a clockwise direction so that the water 
will be circulated in its short circuit to restore heat to the water 
system. 
Using jack screws 24 and 72, movable side channel 14 and movable end 
channel 16 are drawn outwardly permitting the cast concrete member to be 
lifted out of casting bed 10. When movable side channel 14 and movable end 
channel 16 are returned to their original positions, casting bed 10 and 
system 110 are ready for casting another concrete member. 
The design of casting bed 10 is such that with minor design changes to the 
ends of movable side and end channels 14 and 16, the casting bed will be 
adapted to cast concrete panels of widely different dimensions. Of course, 
it should be understood that various other changes and modifications of 
the preferred embodiments described herein will be apparent to those 
skilled in the art. Such changes and modifications can be made without 
departing from the spirit and scope of the present invention and without 
diminishing its attended advantages. It is, therefore, intended that such 
changes and modifications be covered by the following claims.