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SHOCK, Corian and cast marble

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

Manufacturer of raw materials: ACRYLIC PLASTICS, SELF-CONTAINING AST-T, AST-TT, BUTAKRYL - Kharkov enterprise JSC "Stoma".

Kharkov, Newton St., 3. (near the intersection of Gagarin Ave. and Odessa Street).

http://www.stoma.kharkov.ua

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

I would also be grateful for advice on the manufacture of molds.

Write also for any questions and advice. In the future, I will also be happy to exchange information.

AS AN EPIGRAPH

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

Art belongs to the people.

PERSONAL EXPERIENCE

For the test sample used redont-3. It is a raw material in dentistry for the manufacture of bases. Its analogues Etakril and FTORAX. But these materials are convenient only for the sample, as they are produced in a small package (250gr.) And are a bit more expensive compared to the technical acrylic self-hardening plastics AST-T, BUTAKRYL. And they can be freely purchased at building materials stores, and sometimes even at a pharmacy. AST-T and BUTACRYL are sold in a minimum package of 5 kg of powder and 5 liters of liquid, i.e. To gain experience you can practice on small volumes.

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

The powder with the liquid was mixed in appropriate proportions, then rubble was added, or sand and the form was poured. The hardening accelerates in warm air, but when overheated, it turns out poor transparency. I stood for 1 hour at room temperature, and then you can, but not necessarily, be heated 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 laminated parts of chipboard. Strongly clings to the tree and its similar plastics. And there was an idea to make a form from the same plastic and then to miss it with something. But even with paraffin and various oils, it was impossible to break even when gripped in a vice.

These plastics are also used for the manufacture of molds for casting from polyethylene, etc.

The best type of mold for casting was such a way!

Suppose you decide to make a table, or a door, or a gravestone monument. The frame is made of iron of the appropriate form. Well, let's say for the table meter by meter you made a frame with an internal size of meter by meter. It is desirable that this frame was detachable for the convenience of getting the finished product. The inner part of the frame is milled under the profile that you want to give to the edge of the table. And, most importantly, well polished.

This frame go to glass. The glass should be very perfectly wiped. Because at the contact of the casting with glass a perfectly transparent and even glossy surface is formed. And even the usual fingerprint will stick to the casting.

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

Then - again, the reduction in price of the product - you put the chipboard of the appropriate size, but a little less from the frame, into the framed frame, so that along the edges this plate also turns out to be filled with material.

Give an hour to dry and warm up with warm air. After half an hour, everything will finally harden.

And another plus of the final heating is that when cooled, the difference between glass and plastic leads to a good separation. Then you unfix the frame and easily grind down the stains of the hardened oplja - the result of poorly made iron frame.

The fact that you invest in casting chipboard, 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 form of polyethylene or plaster, then the resulting product will have to be polished. But my advice to you is that such a cool cast 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 material again and fill in the damage. This material with itself is so integrally connected 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 of the frame.

One more important detail - when you fill rubble, then sift out from the necessary fraction not only large, but small, or it litters in the form of grains of sand.

CALCULATION OF COST

AST-T and BUTAKRIL cost 210 hryvnia set (5 kg + 5 l). This is about $ 40.

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

Add rubble or sand, and there will be about more than 15 liters.

If you make a cast using chipboard (for example a door or a window sill), with a layer of material to be about 4 mm.

Chipboard 16 mm + 4 mm layer = 2 cm.

In this case, 15 liters will be enough for 3 meters of square products.

You will get that the rubble 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 .

I met the cheapest at $ 200.

It turns out that they fool our brother, as in McDonalds.

RAW MATERIALS

ACRYLIC PLASTICS, SELF-CONTAINING AST-T, AST-TT, BUTAKRIL

For the sample, you can use PROTACRYL, REDONT-3; It is sold in any dental materials, but more expensive than the above. But it is convenient for the sample that is sold in a small package, and AST-T and BUTACRYL are sold in 5 kg of powder and 5 liters 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. You may have other types of technical SELF-CONTAINING ACRYLIC PLASTICS nearby.

If you don’t find relevant materials in your area, please contact: seetoo@ukr.net or resourc@ukr.net , Jura. - I will help in Kharkov.

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

The plant also said that the material, mainly purchased for monuments, molds and fill the base of the machines.

CHARACTERISTICS OF RAW MATERIALS

ACRYLIC PLASTICS, SELF-CONTAINING AST-T, AST-TT, BUTAKRIL

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 and liquid during the preparation of the molding material

Mode of application

Mass shares

Swelling time at t (23 ± 2) ° С, min

Determination of readiness

powder

liquids

1. Pressing a) making models

one

0.4–0.5

10–50

Loss of stickiness

b) shell fixing

-

0.4–0.5

5–50

The appearance of stickiness and thread

2. Free casting

one

0.8–0.9

(with stirring)

Creamy consistency

Recycling acrylic plastics.

Pressing.

The molding mass with a slight excess is placed in the mold. The working part of the mold is pre-lubricated with a thin layer of release material. Silicone fluids, mineral oils are used for metal molds, lacquer (Izokol) - for gypsum ones, wax, acetone-celluloid lacquer, etc. for magnesite compositions.

A mold with a weight set under the press and gradually increase the pressure so that the final design of parts occurred at the lowest yield strength of the molding material. The optimal pressure is 57 MPa. The mold is kept under pressure until the mass is completely cured. The dwell time under pressure depends on the temperature of the mold and the environment (room temperature), as well as on the shape and dimensions of the parts.

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

The curing of acrylic plastics occurs with the release of heat. The temperature inside the mass during curing can reach 100 ° C and higher, depending on the volume of the mass and the amount of liquid. At lower temperatures, the curing process slows down.

Free casting

The molding mass is poured into a mold with an excess. In order to avoid air entrapment by the viscous mass, the filling is carried out quickly, without tearing off the vessel with the mass from the walls of the mold. For more monolithic products, the surface of the mass in 10–15 min. after casting the mold, when the film appears, it is recommended to cover it with cellophane and press it with a small load. The mass with the form of stand up to curing, and then subsequent cooling.

In the manufacture of products of large dimensions, in order to avoid foaming, it is recommended to pour the mass in parts, and each subsequent part must be poured after complete curing and cooling of the previous one.

Injection molding

Filling mass produced using special devices such as syringe devices.

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

Centrifugal casting

Centrifugal casting is used in the production of large-sized parts such as rotation bodies.

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

The form with mass is rotated until it is completely cured. Duration of rotation is about 1.0 - 1.2 hours.

Gluing

Products made of acrylic plastic are well glued. As the 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 glued (pre-degreased) surfaces 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 h. Complete curing in the deep layers occurs after 12–15 h.

Coloring

The dyeing of acrylic plastics is made by mixing powder in a ball mill with pigments of the corresponding colors. When using fat-soluble dyes, they are dissolved in acrylic plastic liquids. Coloring of finished products is made with ready varnishes, oil paints, enamels, etc. using conventional methods.

Mechanical restoration

Products from acrylic plastics are processed by turning, milling, drilling, grinding, polishing, and other methods.

Safety and Health Information.

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

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

CASTING MARBLE

In terms 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 products made of artificial stone fulfills all the requirements for outdoor and indoor use.

Pavement slabs of cast marble, laid on the experimental site 11IIZHB in 1967, and the sidewalk, laid out in the same years in the Brest Fortress, are still in good condition.

In Central Asia, since 1962, the lining of artificial engineering slopes of hydraulic structures from artificial marble is exposed to a strong impact of discharged (60-80%) annual flow and sediment (40-100 thousand m 3 of sediment). During the interfacial periods, the cladding is exposed to the weather and high solar radiation.

One of the areas of application of artificial stone are sanitary ware. Almost all over the world, you can find elements of facades and roofs, window sills, window openings, stair steps, railings, countertops, sinks, bathtubs, toilet bowls made of artificial marble.