Makng a Concrete Gecko (7.5m )
by shaperAl in Workshop > Molds & Casting
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Makng a Concrete Gecko (7.5m )
I was commissioned to produce a concrete model of a gecko for a new housing development.
I am a sculptor,working in wood, steel , bronze , plastics and concrete.
For this project, I did quite a bit of research into high strength mortar mixes ( no stone , just sand / cement )
GECKO Underwoodisaurus Milii
First , catch a gecko. This fellow helped out for a bit. Then I made a maquette...
Maquette
Carved in foam and coated in acrylic plaster and finishing cloth ( fine chopped strand mat )
sketching with 10 mm steel rod
New Studio
Using a ring roller, building the body, welding intersections
Sub Frame
Heavier steel for strength and to bond to slab.
Internal Skin / Hessian /poly Foam Internal
I glued hessian to the inside of each half of the steel work. This was to provide a surface that could accept an internal spray-up of polyurethane foam.The purpose of this was to provide a firm surface to apply the glass and steel fibre reinforced mortar on the outside , through the layers of bird mesh.
Reassembling the Two Halves and Chicken Wire Mesh Application
Chicken wire was stitched on to the steel rod armature. Cast concrete eyeballs fitted.
Mortaring the 25 Mm Skin
The mortar mix was designed in consultation with a concrete engineer from Tasmania.
3 parts sand
1part Portland cement
10% Magnesium Oxide ( high early strength )
Fly ash
steel fibre reinforcing
glass fibre reinforcing
water reducing compound ( the strength of concrete is inversely proportional to the amount of water added or water-cement (w/c) ratio.
After Curing, Acid Staining and Anti Graffiti Coating
I made 6 gum nuts in ferrocement also , to provide scale and to be used as casual seating.
Acid stain in various colours was worked into the surface and finally a coat of anti graf sealer that came from a firm called Gecko Coatings. It seemed appropriate...
Leaving the Studio
Big test ! the gecko, weighing approx. one ton ( 1000kg ) was lifted out of the studio and trucked to its place in a playground. No cracking. The sub frame was anchored to the ground slab and a coating of rubber soft fall was put around .