The total length of a panel is about 10'. The panels are about 5" thick with 3 horizontal #4 rerods and 3 vertical #4 rerods. I put bent #5 rerods in the top for lifting. You can see them in the picture if you look close enough.
Henry, I saw you commented on Chris Franzen's color blending. He uses a eco friendly waterbased stain called EcoStain by Surecrete. There is a technique to getting the marbled effect using darker colors over the lighter color. You would use a cleaner they call SCR. It is acidbased and can remove the waterbased acid in areas leaving a great marbled look. I have done it alot on most of my project.
Hey Henry,thanks.Its acid staining,I started of with a light color stain.I do the wet on wet method and it gives it flow.then I used another color in a spray bottle and worked my way around the top spraying it at an angle wet on wet.The colors were toasted almond,Terra cotta, Forrest green.
the forms for the 3" bullnose are from pacific formliner. they are a super flexible foam the is reuable a few times. when you anchor off the foam your steps are 5 1/2" risers less than 1/2" 90 on the top of the foam (you'll see what i mean when they are in front of you) to anchor off the form attach to your riser either 2x6 or laminated plywood 4(3/8" layer) work great on tight corners. to anchor use 16d galvinized finish nails or smooth ones and nail through they lower part of the form and through the top part i told you to ingore. pull your stakes and leave a trowel thickness under them for ease of removing. pull the 2x6 first from the foam and then careful of the nail through the liner.
timing is cristical. too early the nosing will calapse and too late no stamp. you can also butter up a quick skin coat while everything is wet and use polymer and not water the poly is the glue that will bind the ch to the cement. put stealth fiber in your mix i use both the stealth and rigid for added strength and torch em later. if you get a cracked section complete all your detail and put the foam piece back into it over night at the fibers will grab the piece and hold it there when the concrete shrinks and retouch with color hardener.
don't waste your time or money on steigmeyer. after each use wash off and or quick touch with a pressure washer before you go home they average about 50 a 9' piece where i am. i also tried the abs too just too much silcone and back bracing so would flex. and then steig no reusing and wasted money. also you want to vibrate real quick when after you screed off the steps for your almost final pass this will push it into the bullnose and you can also hand pack it with a mag float and no bigger than a 3/8" aggr in the mix you want all the cream possible. goog luck and let me know if you have trouble practice step or two at your house and youll see what is mean
What's news Henry?
I'm still slowly cobbling together material for GRC in Australia (no one does it here) between work times!
Hope all is well in Canada eh I've been away 3 years now and I miss it sometimes... I'll cheer Australia for the Olympics though! Canada can't wait for 2010 winter Olympics I bet - right some wrongs...
Hey Henry, I use a limestone mix that we have been using for a few years. We developed the mix ourselves. We are going to start selling training DVD's soon on all of our limestone methods.
Thanks for the comment.
GFRC new. But No i have been doing wet casting for about 8 years. I have two partners my uncle and cousin.
My uncle did his first one for my parents house in '95.
To be honest though we really just in the last year or so started trying new mixes (plasticizers , fibers, etc.) before that it was just concrete with rebar and mesh. It seemed to work just fine. And we had very little problems.
As my cousin and I get older we are taking more of the business responsibility than before and we are really trying to do our research. I am really exited where its going.
Henry, I saw your post about fiber optics. Did you ever cast one with fiber optic lights? I posted a pic of one of the first ones we did. We are also working on a sign for our shop. Similar concept. We used a 4'x8' sheet of foam and routered out our name, and then around the name added fiber optic lights. Still working on the final touches. Hope to have it up early next week.
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