10-18-2013, 08:07 PM
Certainly can document it seeing as your interested.
I pour a regular concrete base about 1 1/2 thick, it contains rebar around the edges and 6 x 6 mesh through the body. This concrete is strengthened with fiberglass chop and I use water reducer or plasticizer depending on where I get it. Think this makes a big difference, from what i've read micro cracks are common and accepted, I've never had them in the ones I've poured, now it will happen. Then I pour a 3/4 inch layer of decretive stone and cement with no sand. Sand separates the stone chips. I've been using white portland for this part, you can then dye it with powdered dies for mortar. The white base gives truer colours. Again i use water reducer in this mix.
Once this is set the grinder comes in, I cut about 1/4 inch off the top to expose the decretive stone. The first one I did with an angle grinder, worked BUT you need to do this wet and Makita grinders aren't water proof. I had to wear rubber boots and rubber gloves to insulate me from ground. Then its polished with diamond pads to 3000 grit, again wet. I was spitting sparks by the time i was done.
I built a makeshift grinder with a totally enclosed 2 hp motor for the last one, it ran on 5x5 angle on the floor. It worked well but filled the shop with stone dust even spraying the wheel with a garden hose. I also bought a Makita wet polisher, it worked really well, and no spitting sparks.
Will post as we go this time, have the forms built, will get pictures tomorrow.
I pour a regular concrete base about 1 1/2 thick, it contains rebar around the edges and 6 x 6 mesh through the body. This concrete is strengthened with fiberglass chop and I use water reducer or plasticizer depending on where I get it. Think this makes a big difference, from what i've read micro cracks are common and accepted, I've never had them in the ones I've poured, now it will happen. Then I pour a 3/4 inch layer of decretive stone and cement with no sand. Sand separates the stone chips. I've been using white portland for this part, you can then dye it with powdered dies for mortar. The white base gives truer colours. Again i use water reducer in this mix.
Once this is set the grinder comes in, I cut about 1/4 inch off the top to expose the decretive stone. The first one I did with an angle grinder, worked BUT you need to do this wet and Makita grinders aren't water proof. I had to wear rubber boots and rubber gloves to insulate me from ground. Then its polished with diamond pads to 3000 grit, again wet. I was spitting sparks by the time i was done.
I built a makeshift grinder with a totally enclosed 2 hp motor for the last one, it ran on 5x5 angle on the floor. It worked well but filled the shop with stone dust even spraying the wheel with a garden hose. I also bought a Makita wet polisher, it worked really well, and no spitting sparks.
Will post as we go this time, have the forms built, will get pictures tomorrow.
Free advice is worth exactly what you payed for it.
Greg
Greg