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SHOCK, Corian and Cast Marble

By design and product samples: http://www.novoteh.ru - I strongly advise you to see the pictures.

Raw materials producer: ACRYLIC, SELF-CURING PLASTICS AST-T, AST-T-T, BUTAKRIL - Kharkov enterprise JSC "Stoma".

Kharkov, st.Newton, 3. (near the intersection of Gagarin Ave. and Odesa St.).

http://www.stoma.kharkov.ua

A big request - if you find another use for this material, then share the idea. seetoo@ukr.net or resourc@ukr.net , Jura.

I would also be grateful for the tips on making molds.

Write also on any questions and tips. In the future, I will also be happy to share information.

AS EPIGRAPH

I was surprised to find that Egyptian pyramids, steles, monuments and other architectural structures were built using similar technology. Therefore, no company, whether the creators of SHOCK, Corian, etc., can claim copyright.

Art belongs to the people.

PERSONAL EXPERIENCE

For the test sample, REDONT-3 was used. It is a raw material in dentistry for the manufacture of bases. Its analogues are ETACRYL and FTORAX. But these materials are convenient only for testing, since they are available in small packaging (250g.) And are slightly more expensive in comparison with the technical acrylic self-hardening plastics AST-T, BUTACRYL. And they can be freely purchased in building materials stores, and sometimes even in a pharmacy. AST-T and BUTACRYL are sold in a minimum package of 5 kg of powder and 5 l of liquid, i.e. to gain experience you can train on small volumes.

As a filler, I used finely broken crushed stone (up to 4 mm). You can use ordinary sand, colored gravel and sand.

The powder and liquid were mixed in the appropriate proportions, then crushed stone was added, or sand and the mold was poured. Hardening is accelerated in warm air, but when overheated, poor transparency is obtained. I kept it for 1 hour at room temperature, and then it is possible, but not necessary, to warm it in warm air (approximately +40 0 )

The main specificity and complexity lies in the manufacture of the mold for casting.

This mass freely lags behind polyethylene, metal, glass and the laminated particleboard. It grips tightly with wood and similar plastics. And there was an idea to make a mold from the same plastic and then grease it with something. But even when smearing with paraffin and various oils it was impossible to break even when clamped in a vice.

These plastics are also used to make molds for casting from polyethylene, etc.

The best kind of mold for casting was this way!

Suppose you decide to make a table, or a door, or a tombstone. An iron frame of the appropriate shape is made. Well, let's say for a meter per meter table, you made a frame with an internal size of meter per meter. It is desirable that this frame be detachable for ease of delivery of the finished product. The inner part of the frame is milled to the profile that you want to give the edge of the table. And, most importantly, it is well polished.

This frame lay on the glass. Glass should be very perfectly wiped. Because on contact of the casting with glass, a perfectly transparent and even glossy surface is formed. And even a regular fingerprint will stick to the cast.

Then, a mixture of material with gravel or the filler that you choose is poured into the frame. In the amount of gravel you can not be shy. The more - the less material consumption.

Then - again, cheaper products - put in a flooded frame chipboard plate of the appropriate size, but slightly less than the frame, so that along the edges this plate is also flooded with material.

Allow an hour to dry and warm with warm air. In half an hour everything will finally harden.

And another plus of the final heating is that when cooling, the difference between glass and plastic leads to a good separation. Then you unfasten the frame and easily grind the smudges of the hardened braze - the result of a poorly made iron frame.

What you invest in chipboard casting not only reduces the cost of the product, but also simplifies further design work. By the way, this material can be cut, drilled, milled, etc. I do not recommend painting this material. It is better to paint the filler.

If you made a mold from polyethylene or gypsum, then the resulting product will have to be polished. But my advice to you is that such a cool casting is obtained on glass that no polishing can be achieved.

If any type of damage has occurred on the finished product, do not despair. Dissolve some more material again and fill in the damage. This material combines with itself so holistically that it again becomes a monolith.

A little advice - the frame on the glass can be fixed with double-sided tape. It will prevent material from flowing out from under the frame.

Another important detail - when you fill gravel, then sift from the desired fraction not only large, but small, otherwise it will clog in the form of grains of sand.

CALCULATION OF COST

AST-T and BUTACRYLES cost 210 hryvnias a set (5 kg + 5 l). This is about $ 40.

When mixing the components 5 kg + 5 l = 9.5 liters.

Add crushed stone or sand, and about 15 liters will come out.

If casting is done using chipboard (for example, a door or window sill), the material layer should be approximately 4 mm.

Particleboard 16 mm + layer 4 mm = 2 cm.

In this case, 15 liters is enough for 3 meters of square product.

It turns out that the crushed stone is free, chipboard costs a penny.

Here comes the cost of 3 m 2 = $ 40. Let 1 m 2 = $ 14.

And finished products, if you look on the Internet, cost $ 400-600 m 2 .

The cheapest I have met for $ 200.

So it turns out that they are fooling our brother, as in McDonald's.

RAW MATERIALS

ACRYLIC, SELF-CURING PLASTICS AST-T, AST-T-T, BUTACRYL

For the test, you can use PROTACRYL, REDONT-3; it is sold in any dental materials, but more expensive than the above. But it is convenient for testing in that it is sold in a small package, and AST-T and BUTACRYL are sold at 5 kg of powder and 5 l of liquid. Also suitable are any acrylic self-hardening plastics used for the manufacture of bases in dentistry such as ETACRYL and FTORAX.

But it is all more expensive compared to AST-T and BUTACRYL, and can only be used for testing. Perhaps other types of technical SELF-HARDENING ACRYLIC PLASTICS are produced nearby.

If you do not find the relevant materials at home, then write: seetoo@ukr.net or resourc@ukr.net , Jura. - I will help in Kharkov.

When I took the material from the factory, I found out that Belarusians buy a lot of BUTACRYLA. BUTACRYL is somewhat more transparent than AST-T, although I used AST-T.

The factory also said that the material is mainly purchased for monuments, molds and pouring the base from machine tools.

CHARACTERISTICS OF RAW MATERIALS

ACRYLIC, SELF-CURING PLASTICS AST-T, AST-T-T, BUTACRYL

Preparation of the molding material of acrylic plastics.

The molding mass of acrylic plastics is prepared by mixing powder and liquid in the ratios indicated in the table - The ratio of powder to liquid in the preparation of the molding mass

Mode of application

Mass fraction

Swelling time at t (23 ± 2) ° С, min

Readiness Definition

powder

liquids

1. Pressing a) production of models

one

0.4–0.5

10-50

Stickiness loss

b) shell seal

-

0.4–0.5

5-50

The appearance of stickiness and threads

2. Free casting

one

0.8–0.9

(with stirring)

Creamy consistency

Recycling acrylic plastics.

Pressing.

The molding material is placed in a mold with a slight excess. The working part of the mold is pre-lubricated with a thin layer of release material. Organosilicon liquids, mineral oils are used for metal molds, varnish (Isokol) is used for gypsum molds, wax, acetonecelluloid varnish, etc. are used for magnesite compositions.

The mold with the mass is installed under the press and the pressure is gradually increased so that the final decoration of the parts occurs at the lowest fluidity of the molding material. The optimal pressure is 57 MPa. The mold is kept under pressure until the mass is completely cured. The exposure time under the press depends on the temperature of the mold and the environment (room temperature), as well as on the shape and size of the parts.

To accelerate the curing of the molding material, the mold under the press can be maintained at a temperature of 25 - 30 ° C.

Acrylic plastics cure with heat. The temperature inside the mass during curing can reach 100 ° C and above, depending on the volume of the mass and the amount of liquid. At low temperatures, the curing process slows down.

Free casting

The molding material is poured in excess. In order to avoid capture of air by a viscous mass, pouring is carried out quickly, without tearing the vessel with mass from the walls of the mold. To obtain more monolithic products, the surface of the mass in 10-15 minutes. after pouring the mold, when the film appears, it is recommended to cover with cellophane and press down with a small load. The mass with the form is kept until curing, and then subsequent cooling.

In the manufacture of large-sized products, in order to avoid foaming, it is recommended to fill the mass with parts, and each subsequent part must be filled after the previous one has completely cured and cooled.

Injection molding

The filling of the mass is carried out using special devices such as syringe devices.

Depending on the size of the shape of the forming cavity, devices are developed individually.

Centrifugal casting

Centrifugal casting is used in the manufacture of large parts such as bodies of revolution.

The equipment for the production of parts can be universal metal-cutting and woodworking machines (turning, drilling, etc.) or special devices on which appropriate forms are installed.

The mass form is rotated until the cure is complete. Duration of rotation is approximately 1.0 - 1.2 hours.

Gluing

Acrylic plastic products adhere well. As glue, solutions of crushed organic glass of 2-3% in dichloroethane, glacial acetic acid, chloroform, etc. are used.

A uniform layer of glue is applied to the surfaces to be glued (previously degreased) with a soft brush, after which the parts are clamped with clamps. The clamping pressure is 0.1 - 0.3 MPa, the curing time is 0.5 - 1.0 hours. Full curing in the deep layers occurs after 12 - 15 hours.

Dyeing

Acrylic plastics are dyed by mixing powder in a ball mill with pigments of the corresponding colors. When using fat-soluble dyes, the latter are dissolved in a liquid of acrylic plastics. Coloring of finished products is done with finished varnishes, oil paints, enamels and other conventional methods.

Mechanical restoration

Acrylic plastic products are processed by turning, milling, drilling, grinding, polishing and other methods.

Safety and industrial hygiene information.

Work with acrylic self-hardening plastics should be carried out in compliance with fire safety rules when working with flammable liquids.

MPC of liquid vapor of acrylic self-hardening plastics (methacrylic acid methyl ester) in air 10 mg / m3, flash point 80 ° С.

CASTING MARBLE

From the point of view of chemistry, polymer concrete is a cured, highly filled polyester resin (18-21% resin and 78-81% quartz sand or other inert mineral filler).

According to the conclusion of the Finnish company NESTE Chemicals, the protective and decorative coating of artificial stone products fulfills all the requirements necessary for use on the street and in the premises.

Paving slabs made of cast marble, laid on the experimental site of IIIIZhB in 1967, and the pavement laid in the Brest Fortress in those same years are still in good condition.

In Central Asia, since 1962, artificial marble cladding of slopes of hydraulic structures, exposed to strong impact of discharged (60-80%) annual runoff and bottom sediment (40-100 thousand m 3 of sediment). During flood periods, the lining is exposed to atmospheric effects and high solar radiation.

One of the areas of application of artificial stone is plumbing products. Almost all over the world you can find elements of facades and roofs, window sills, window openings, staircases, railings, countertops, wash basins, bathtubs, and toilet bowls made of artificial marble.