07-06-28

Attach:D038_TileProductionOnWoodAndPlasticTileMoldReinforcementOverview.jpg Δ | Mold on wood and plastic

  • On a planed board of 120 x 24 cm molds were made for 4 15 x 20 tiles and an impulse valve tile.
  • The plastic was pulled straight as much as possible
  • The beams were nailed onto the board with 1" nails
  • With the PDF template for the holes Δ the holes were made in to the wood with a nail.
  • The paper was removed and half length bicycle spokes were put into the holes left by the nail
  • Steel wire recuperated from car tires was wound over the spokes.
  • The wire had not been softened enough by heating and was did not bent easily.


Attach:D038_TileProductionOnWoodAndPlasticFilledMold.jpg Δ | Filled tile mold

  • The mold was filled with a 'soil moist' mixture of 1 cement and 3 sand.
  • The U-shaped connection reinforcement were put in after filling the mold.
  • With a piece of wood air bubble were removed by softly hitting the surface.


Attach:D038_TileProductionOnWoodAndPlasticPosistioningWedge.jpg Δ | Positioning the cut sheet metal wedge mold

  • The dimensions of the wooden wedge were cut out of sheet metal.
  • One side was bend by stone chisel
  • Two 3" nails were hammered in the middle and on the wooden board on the right position.


Attach:D038_TileProductionOnWoodAndPlasticWedgeStabilization.jpg Δ | Stabilization of the sheet metal wedge

  • The other sides were bend as well
  • The corners were 'sewed' together with iron wire
  • Because the wedge had the tendency to topple over the positioning nails were bend to both sides.


Attach:D038_TileProductionOnWoodAndPlasticWedgeMoldeDetail.jpg Δ | Reinforcement detail and mounting PE tubes

  • Spokes were put as well on several places, without PDF-paper sheet
  • 'Normal' iron wire was woven around it.
  • This also appeared to be 'jumpy'.
  • The PE tubes were clamped between the wire and the wooden battens.


Attach:D038_TileProductionOnWoodAndPlasticWedgeReinformentOverview.jpg Δ | Filled impulse valve tile mold

  • The plastic was pulled again to make it more straight.
  • The mold was filled with a mixture of 1 cement on 3 sand
  • After filling the U-shaped connection reinforcements were placed


Attach:D038_TileProductionOnWoodAndPlasticTileUsefullResult.jpg Δ | Result of casting on plastic, looks well

  • After 24 hours the spokes were removed from all the tiles by slowly turning and pulling
  • This tile looked useable from the outside.


Attach:D038_TileProductionOnWoodAndPlasticResultUseless.jpg Δ | Result of casting on plastic, not looking well

  • This tile doesn't look well, there is a part missing next to the ring.
  • More attention should be paid to removing air bubbles.


Attach:D038_TileProductionOnWoodAndPlasticWedgeTileOverview.jpg Δ | Result of casting on plastic, looking well

  • The impulse valve tile generally looked well and could function
  • Some concrete flowed under the wedge, but this rim could be removed after the concrete is completely hardened.


Attach:D038_TileProductionOnWoodAndPlasticWedgeTileDetail.jpg Δ | Result, detail of valve tile

  • Some parts show wrinkles of the plastic, but they're at some distance of the vital parts.
  • The little hole of the spoke could leak some concrete.


Attach:D038_TileProductionOnWoodAndPlasticRemovingWaxRing.jpg Δ | Removing the candle wax ring with a little fire

  • The wax rings were removed by keeping both sides of the tile a little while above a small fire of wood splints.
  • After that the ring could be pushed out entirely.
  • It's favorable to leave the ring in the tile, until the pipes are cast. From the outside it's well to judge if the tile is alright or no. Small air bubbles can be fixed with some cement afterwards.


Attach:D038_TileProductionOnWoodAndPlasticFilledResultUseableTile.jpg Δ | Detail of the hole surface

  • This is the usable tile from the above picture.
  • The picture shows the worst side, which contains air bubbles.


Attach:D038_TileProductionOnWoodAndPlasticResultUselessTile.JPG Δ | Detail of the hole surface

  • This is the unusable tile from the above picture.
  • The picture shows the worst side, which contains air bubbles.
  • Although it contains less air bubbles, the rim is difficult to repair.

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Page last modified on July 15, 2007, at 08:23 AM