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mixture was very dry initially, water and cement were Total Weight
Total Volume
325.3 lb
2.2 ft^3
added in 0.4:1.0 until the mixture was workable. The
final proportions have the same 0.40 ratio, but have an additional 20.5 lb of water and 50 lb of
cement. The final proportions are shown in Table 2; the total volume of the final mix was
estimated to be 3.1 ft3. The estimated volume for two benches is 7.6 ft3, so 2.5 batches, or 7.75 ft3,
of
Table 2 Final Concrete Mix for one Table 3 Total amount of material mixed
bench for two Benches
Final 0.40 Proportions
Water 28 lb Lab Four Concrete Weights
Cement 120 lb Batch 1 Batch 2 Batch 3 (Half)
Sand 88.9 lb Sand (lb) 95 100 45
Coarse Aggregate 138.4 lb Coarse Aggregate (lb) 138.5 139 69
% Moisture 2 % Water (lb) 47 48 24
Cement (lb) 120 120 60
Actual Sand 90.8 lb
Water:Cement Ratio 0.39 0.40 0.40
Actual Water 46.7 lb
Approximate Total
Total Weight 395.9 lb Volume (ft^3) 3.1 3.1 1.55
Total Volume 3.1 ft^3
concrete were mixed. The proportions of each
batch are shown in Table 3; the average water to cement ratio was 0.40.
Mold Filling and Finishing: The well mixed concrete was shoveled into the bench
molds carefully so that the reinforcement skeleton was not dislodged and the concrete filled all
spaces adequately. To ensure proper filling in tight spaces, a rod
compacted the concrete as shown in the image below. This let
air escape to reduce and eliminate air pockets in the mold.
Tapping of the form with a
hammer also aided in releasing air
pockets within the concrete. Once
the mold was adequately filled, the
surface was worked to bring
Figure 7 Filling the Form
with concrete
smooth cream to the top of the
surface. Exposed edges of the
mold were pressed to reduce a
profound and painful edge. Note, the finishing process occurred Figure 8 (left) : finishing
after excess moisture disappeared in the bench (this took hours the surface, (right):
after the last shovel of concrete was added to the mold). removing trapped air
within the concrete
Acid Etching: The final step in the concrete bench
construction was to stain the concrete using a process known as acid etching. This is a chemical
reaction in which the stain is applied to the cured concrete. The acid penetrates into the concrete
and allows the coloring to be absorbed deep into the bench, providing a variety of colors and a
surface finish similar to marble.
The process of acid etching is remarkably simple. The bench surface is first cleaned
with water to remove any surface dust or contaminates. The acid is then applied either with a
sprayer, brush, or in our case a rag. The acid is poured onto the
surface slowly and wiped around so as not to have any puddles
of the acid sitting since that will cause areas of serious
discoloration. The top surface of the bench was relatively easy
to stain since the acid was easier to manipulate and spread.
The vertical sides of the bench were trickier since the acid just
wanted to run down the sides so that it didn’t have time to
penetrate. Several different techniques were used to try to
apply the acid to the sides with no single method working
Figure 9 Concrete Bench after better than the rest. The simplest was to pour the acid onto the
acid etching
rag and then apply it to the bench, this resulted in a little waste
but overall was very effective.
The final appearance of the bench was a reddish golden color with the desired marble
look. The clean up was simple and the final step was to rinse off any acid residue and apply a
concrete sealer to protect the stain and give a satin surface finish to protect the color. The
process was simple, effective and cheap ($80 for acid and sealer) and was more than enough to
stain and seal two benches.
Conclusion: The modified design resulted in less air bubbles being trapped under the form on
the top. The acid etching provided a very provided a good finish after the concrete has cured.
Some recommendations for next year would be to bevel the edges of bench through form
modification. Another recommendation might be to experiment with different colored stains.