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SHOCK, Corian and Injection Marble

According to the design and samples of products: http://www.novoteh.ru - I strongly advise to see the pictures.

Producer of raw materials: ACRYLIC PLASTICS, SELF-CURING AST-T, AST-T-T, BUTAKRIL - Kharkov enterprise JSC "Stoma".

Kharkov, Newton Street, 3. (next to the intersection of Gagarin Avenue and Odesskaya Street).

http://www.stoma.kharkov.ua

The big request - if you find another application to this material, then share an idea. seetoo@ukr.net or resourc@ukr.net , Yura.

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

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

AS THE EPIGRAPHER

I was surprised to find that Egyptian pyramids, stellas, monuments and other architectural structures were built using this technology. Therefore, no firm, whether creators of SHOCK, Corian, etc., can not claim copyright.

Art belongs to the people.

PERSONAL EXPERIENCE

REDONT-3 was used for the test sample. It is the raw material in dentistry for making bases. Its analogs are Etacryl and Fluorax. But these materials are convenient only for the sample, since they are produced in a small package (250 gr.) And slightly more expensive than the technical acrylic self-hardening plastic AST-T, BUTAKRIL. And they can be freely purchased in the stores of building materials, and sometimes even in the pharmacy. AST-T and BUTAKRIL 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 crushed stone (up to 4 mm). You can use ordinary sand, painted rubble and sand.

The powder with the liquid was mixed in the appropriate proportions, then crushed stone or sand was added and the mold was poured. Hardening accelerates in warm air, but with overheating, poor transparency is obtained. I stood for 1 hour at room temperature, and then it is possible, but not necessary, to warm up in warm air (about +40 0 )

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

This mass freely lags behind polyethylene, metal, glass and laminated part of particleboard. Firmly grasps the wood and similar plastics. And there was an idea to make a mold from the same plastic and then to smear it with something. But even with lubricating with paraffin and various oils it was impossible to break even when squeezed in the vice.

These plastics are also used for making molds for casting from polyethylene and the like.

The best form of mold for casting was this way!

Suppose you decide to make a table, or a door, or a tombstone. A frame made of iron of appropriate shape is made. Well, for example, for a table meter per meter you made a frame with an internal meter size per meter. It is desirable that this frame was detachable for easy delivery of the finished product. The inside of the frame is milled to the profile that you want to give the edge of the table. And, most importantly, well polished.

This frame lies on the glass. Glass should be very perfectly rubbed. Because on the contact of the cast with the glass an ideally transparent and even glossy surface is formed. And even the usual fingerprint will stick to the casting.

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.

Further - again, the price reduction of the product - you put in the filled frame a chipboard of the appropriate size, but slightly less from the frame, so that at the edges of this plate, too, was flooded with material.

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

And one more plus of final heating is that when cooling the difference between glass and plastic leads to their good separation. Then unfold the frame and easily grind off the stains of the hardened bast hole - the result of a poorly made iron frame.

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

If you made a mold made of polyethylene or gypsum, the resulting product will have to be polished. But my advice to you - on the glass you get such a cool cast that no polishing can be achieved.

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

A small tip - the frame on the glass can be attached with double-sided tape. It will prevent the flow of material from under the frame.

Another important detail - when you fill rubble, then screen out the necessary fraction not only large, but small, or it clogs up in the form of grains of sand.

CALCULATION OF COST

AST-T and BUTAKRIL cost 210 UAH kit (5 kg + 5 l). That's about $ 40.

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

Add rubble or sand, and will come out about more than 15 liters.

If you make castings using chipboard (for example, doors or windowsills), with a layer of material to be about 4 mm.

Particleboard 16 mm + layer 4 mm = 2 cm.

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

At you it will turn out, that rubble is free, ДСП there are copecks.

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

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

The cheapest I met at $ 200.

So it turns out that our brother is being fooled, as in McDonald's.

RAW MATERIALS

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

For the sample, you can use PROTACRIL, REDONT-3; it is sold in any dental materials, but more expensive than the above. But it is convenient for the trial in that it is sold in a small package, and AST-T and BUTAKRIL sell 5 kg of powder and 5 l of liquid. Also suitable are any acrylic self-hardening plastics used for making bases in dentistry such as Etacryl and Fluorax.

But this is all more expensive compared to AST-T and Butacryl, and can only be used for testing. Perhaps you have other types of technical self-hardening ACRYLIC PLASTICS available nearby.

If you do not find the appropriate materials for yourself, write: seetoo@ukr.net or resourc@ukr.net , Yura. - I will help in Kharkov.

When I took the material at the plant, I learned that Belarusians bought a lot of BUTAKRILA. BUTAKRIL is somewhat more transparent than AST-T, although I used AST-T.

The plant was also told that the material is mainly bought for monuments, molds and pouring the foundations of the machines.

CHARACTERISTICS OF RAW MATERIAL

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

Preparation of a molding compound of acrylic plastics.

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

Mode of application

Mass shares

Swelling time at t (23 ± 2) ° С, min

Determining readiness

powder

fluids

1. Pressing a) making models

1

0.4-0.5

10-50

Loss of stickiness

b) shell sealing

-

0.4-0.5

5-50

Appearance of stickiness and filaments

2. Free casting

1

0.8-0.9

(with stirring)

Creamy consistency

Processing of acrylic plastics.

Pressing.

The molding mass is placed in the mold with a small excess. The working part of the mold is pre-lubricated with a thin layer of separating material. For metal molds, organosilicon fluids, mineral oils are used, for gypsum varnishes (Izokol), for magnesite compositions - wax, acetone-celluloid varnish, etc.

The mold with the mass is placed under the press and the pressure is gradually increased so that the final registration of the parts takes place with the least fluidity of the molding mass. The optimum pressure is 57 MPa. The mold is kept under pressure until the mass is completely cured. The holding time under the press depends on the mold temperature and the surrounding environment (room temperature), as well as on the shape and dimensions of the parts.

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

Curing of acrylics occurs with the release of heat. The temperature inside the mass upon curing can reach 100 ° C or higher, depending on the volume of the mass and the amount of liquid. At low temperatures, the curing process slows down.

Free casting

The molding mass is poured into the mold with excess. To avoid entrapment of air by a viscous mass, the pouring is performed quickly, without tearing off the vessel with mass from the walls of the mold. To obtain more monolithic products, the surface of the mass after 10-15 minutes. after filling the mold, when the film appears, it is recommended to cover with cellophane and press it with a small load. The mass of the mold is kept until cured and then cooled down.

When making products of large dimensions, in order to avoid foaming, it is recommended that the mass is poured in parts, each subsequent part must be poured after fully curing and cooling the previous one.

Injection molding

The mass is filled with special devices such as syringe devices.

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

Centrifugal casting

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

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

The mold with the mass is rotated until the latter solidifies. The rotation time is about 1.0 - 1.2 h.

Gluing

Products made of acrylic plastics are well bonded. As glue, solutions of crushed organic glass 2-3% in dichloroethane, glacial acetic acid, chloroform, etc. are used.

On glued (pre-degreased) surface with a soft brush apply a uniform layer of glue, after which the parts are clamped with clamps. Clamping pressure 0.1 - 0.3 MPa, curing time 0.5 - 1.0 h. Full hardening in the deep layers occurs in 12 - 15 hours.

Staining

Staining of acrylic plastics is done by mixing in a ball mill a powder with pigments of appropriate colors. When using fat-soluble dyes, the latter are dissolved in a liquid of acrylic plastics. The finished products are painted with ready-made varnishes, oil paints, enamels and other conventional methods.

Mechanical restoration

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

Information on safety precautions and industrial sanitation.

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

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

CASTING MARBLE

From the point of view of chemistry, polymer concrete is a cured high-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 outdoor and indoor use.

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

In Central Asia, since 1962, the cladding of artificial marble from the slopes of hydraulic structures has been subjected to a strong impact of the discharged (60-80%) annual runoff and bottom sediments (40-100 thousand m 3 of sediment). During the interfowl periods, the lining is exposed to atmospheric influences 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, stairs, rails, countertops, wash basins, bathtubs, toilet bowls made of artificial marble.