CSA Aircrete Lightweight Concrete Garden Boxes – PART 3.7

CSA Aircrete Formula – 3rd Test Batch

In the third mix I upped the cement ratio. It’s now 20 lbs of Cement All, 4 lbs of water, about the same amount of foam, 2 teaspoons of plasticizer, and a bit of fiber.

aircrete formula and ingredient blend for this test batch
Increase the density in last CSA Aircrete formula

And I’ll add charcoal liquid colour to the water this time.

adding concrete colour dye tint to the wet concrete
Black liquid cement dye used this time

Once well blended I add the foam and mix that in well.

pouring CSA aircrete into a mold
And last test aircrete into the plywood form

And then pour it into the form. Shaking it to settle the CSA aircrete. After it begins to thicken I added the wire grid. I pressed this in and smooth with a trowel.

laying in wire grid for reinforcement
Grid layed in and gently pushed into center of casting

When the CSA aircrete began to warm, and the surface dried with a white haze, I sprinkled water over it. I repeated this for an hour. Keeping the surface wet as it cured. I covered them with plastic and left them overnight.

CSA cement hardens quickly and generates heat
CSA concrete warming and drying

Water Curing

CSA concrete gets watered while curing
One hour water curing CSA Aircrete

Stripping the Forms

The next morning I stripped the forms from the castings. I remove all the screws from the form, gently wiggle the sides to free them, then remove the panel from the base and stand it on one side. And then remove the ends.

disassemble concrete moulds
Removing screws to disassemble the forms

The sand in the Cement All was noticeable in these panels compared to Portland-based aircrete. And I had hoped that it would make the panels more durable and impact resistant.

stripping the form from the casting
Little wiggling helps to remove the form ends

All the panels came out of the forms well. They all felt sound and solid. Other than some surface blemishes around the panel inset, there were no significant cracks or any signs of warping.

complete csa lightweight concrete garden panel
Good looking casting!

Longer Water Curing

As in my last two videos, these panels where also submerged in water in an improvised tank. They soaked for two weeks then were pulled out and left to slowly dry in my shop for another two weeks.

wet curing the lightweight panels in a water bath
Air crete curing by water submersion
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