User's Manual

®
Cast Beam Structures Set ME-7009
4
Example Tension Fixture
• Make sure that the two Sliding Connectors on the #5 beams are slightly loose so that they can slide freely along the beams.
• Fasten the cord to the Cord Tensioning Clip first and then attach the Clip to the Flat Round Connector.
• Mount the assembled mold and rebar member on the tension fixture. Put slotted masses on the #3 beam at the end of the ten-
sion fixture as a counterbalance. Attach weights up to 100 N (about 10 kilograms) to the end of the cord in order to stress the
rebar member.
Mix the Concrete
• Mix equal quantities of fine sand and plaster of Paris. [NOTE: This mixture will make a fairly weak cast beam. Decrease the
proportion of sand to increase the strength of the cast beam.]
• Add a small amount of water to the mixture and stir the ingredients together.
• Continue to add water and stir until the mixture has the consistency of honey.
Add the Mixture to the Mold
• Carefully pour the mixture into the assembled mold. You can use a spoon to ladle the mixture into the mold.
• Frequently tap the sides of the mold to help the mixture settle and to remove bubbles. Use the spoon to push the mixture down
into the spaces around the rebar member.
• Use a tool such as a table knife or small, flat piece of wood to smooth the top surface of the mixture.
#5
#5
#3
#3
#3
#2
Sliding
Connector
#4
Straight
Connector
Sliding
Connector
Sliding
Connector
Mold
Rebar Member
Flat Round
Cord
Tensioning Clip
#1
#1
Angle
Connector
Angle Connector
#3
#3
Pulley
Medium
Axle
Half
Round
Cord
Weights
#5
Tension Fixture
Assemble the Mold Pour the Plaster Remove the Mold
Rebar Member
Cast Beam
Slotted
Masses