Concrete is a wonderful, hard, neutral, unprecious material with a real presence. And it can be successfully adapted to jewellery. This is an introduction to basic processes and materials.
Grey portland cement with limestone dust, in sterling silver.
2.5″ (6 cm) long. Silver chain.
© 2000 Andrew Goss
Uncured concrete is difficult to handle. It usually needs some kind of form or structure to control the shape. This leads to three completely different fabrication methods:
Concrete is a mix of portland cement, an aggregate, water and other additives that give the mix certain characteristics. Aggregates vary depending on scale, colour, strength:
The dry materials are mixed first. Water is added to the dry mix. Do not add too much water; the drier the mix, the stronger the final product. (Excess water stays trapped in the cured cement.) How wet to make the mi x is a function of the process: casting in a mold will need a wetter mix that slumps into place. Applying the mix to a wire mesh will need a drier mix that feels more like clay and stays in place until it sets.
Concrete will get somewhat hard after 4 to 12 hours, depending on the mix and temperature, and can be worked with coarse files or carved at this stage. In one or two days it becomes harder still, but it is possible to wet sand to refine the shape. After that it becomes comparable to working with stone. It is best to add layers of new concrete within the first day or two after the initial set, when almost complete bonding takes place, but it is possible to add layers for several days.
Don’t be intimidated: cement, sand and water works at a basic level. The materials listed below are for making high-quality concrete.Concrete is a mix of portland cement, aggregates, water and other optional additives that give the mix certain characteristics.
Portland cement is what holds the aggregates together and is available in different grades and colours. The type you can buy at the local hardware or lumber store is grey in colour. White portland cement has the tetracalcium aluminoferrite removed, resulting in a pure white powder, with no loss of strength. It is more expensive.
|Four Ridge Pins:|
Brass, patinated black, and concrete. About 2″ (5 cm) long.
The brass pins were made first and used as molds for the concrete.
1999. © Andrew Goss
Concrete mixes are variable, and specific to certain applications. As a general rule, the larger the final piece the larger the aggregate. These are basic mixes that I have used and developed over time and work well in terms of plasticity, compressive strength, density and finishing characteristics. I have not suggested liquid volumes as they are too variable (depending on moisture content of the sand etc.) but the general rule is to use as little as you can get away with. You can experiment with the basic mix: more cement will make the mix more plastic, but you will have more shrinkage; more aggregate lessens the shrinkage but will make the mix more crumbly.
Always mix the dry ingredients well first. Then slowly add the liquid, stirring with a stick — don’t use soft wood. For small mixes (jewellery scale) I use plastic containers. My apologies for mixing metric and teaspoon measurements, but for the record a teaspoon (tsp) is 5 ml and tablespoon (tbsp) is 15 ml.
This mix works well casting into small metal molds, or applying around a steel mesh armature.
Sift the stone dust and cement and metakaolin through a sieve to remove lumps. The cement is mixed well with all the dry ingredients, then thoroughly wetted, but not sloppy. This means a consistency as much like clay as you can get. If it is placed in the mold it can be a bit wetter. If it is applied to a metal armature, it can be more like clay. Then cover it with plastic wrap for 24 hours, making sure the surface does not get dry. After this period it can be uncovered and wet sanded to shape. Small air holes can be filled with a mix of the same proportions and covered for another day then wet sanded again. After a weeks curing (covered, or submerged in water, not allowed to dry out) it can be sealed.
Contrary to how a lot of contractors deal with it, concrete can be hazardous to your health. Cement is extremely caustic when mixed with water and not cured, so use common sense. This means it will burn your skin. Wear protective gloves and glasses or goggles. The dust, either from mixing cement and sand, or from sanding dry concrete, is toxic (free silica, chromium contaminants). Wear an appropriate mask or respirator (one approved for toxic dust). Always wet sand rather than dry sand whenever possible.
“Allergic dermatitis” means that once you develop a sensitivity to cement, in the form of a skin allergy, you may not be able to use it any more. So use preventive measures to make sure you do not develop the sensitivity in the first place. Check the Material Safety Data Sheets for whatever materials, additives or sealers you are using.
Never wash cement off your tools in the sink or it will clog the drains. Always use a bucket of water. Let it settle a day before pouring off the water and disposing of the hardened cement and sludge.
Cement and sand are usually available from local hardware and lumber suppliers as well as masonry suppliers. For steel mesh (sometimes called hardware cloth) try a hardware store. Ask for the 1/8″ mesh if you’re doing jewellery. You can also use glass mesh or scrim, from sculpture suppliers. Acrylic admixture or additive is a liquid now found at Home Depot and other large suppliers, in the masonry section.
For stone dust, try a local stone quarry if you are lucky enough to be near one. You can often find limestone dust (sold as dolomite) in the gardening section of hardware stores; it is sold as a soil sweetener to counter acidity. Sealers can be found in hardware and lumber stores, as well as masonry suppliers.
For plastic fibres you may have to contact a local redi-mix plant and see if they will sell you a one pound bag – enough for years of jewellery making. Pozzolans (like metakaolin) are the biggest problem to find. You may have to buy a huge bag. Try a local pool builder; they sometimes use it to add to their mixes plastering the inside of pools.
Lastly: More details and sources are available at http://www.makersgallery.com