A-STONE polymer gypsum (two-component)

A-STONE is an innovative product that consists of two components: high-strength gypsum and acrylic resin. The combination of these ingredients creates a material with excellent strength, which is environmentally friendly and flame-retardant. With A-STONE it is possible to create moulds and casts of any shape and structure. In addition, by laminating, high-strength components can be obtained while maintaining low weight. The manual application of this product enables artists and architects to create unique designs.

PHYSICAL AND CHEMICAL PROPERTIES

A-STONE is a two-component composition with a resin/powder mixing ratio of 1:3 (1000gr powder : 330 gr resin).

Once cured, it has a density of 1.7 g/cm3.

Product life is 8-15 minutes and de-moulding can be carried out within 40-90 minutes.

After curing, A-STONE achieves a compressive strength of ~50 MPa.

Colour - natural white.

It is fireproof.

The Shore D hardness is 83.

A-STONE has excellent UV resistance.

Packaging:

1 kg - 0.75 kg powder + 0.25 kg resin (100gr powder : 30-33gr resin = 750gr powder : 225-250gr resin)

2 kg - 1.5 kg powder + 0.5 kg resin (100gr powder : 30-33gr resin = 1500gr powder : 450-500gr resin)

8 kg - 6 kg powder + 2 kg resin (100gr powder : 30-33gr resin = 6kg powder : 1.8-2kg resin)

16 kg - 12 kg powder + 4 kg resin (100gr powder : 30-33gr resin = 12kg powder : 3.6-4kg resin)

32 kg - 24 kg powder + 8 kg resin (100gr powder : 30-33gr resin = 24kg powder : 7.2-8kg resin)

How do I calculate the amount of polymer gypsum and resin required?

New mould? Measure its volume with water and then calculate the values for obtaining the proportions of the ingredients.

All values are given in grams.

X - volume measured with water, grams

G - weight of gypsum (powder - component A), grams

W - weight of resin (resin component B), grams

G=X*1.42

W=G*0.3 or (0.33)

Example 1:

I have 180 gr of water in the mould:

Weight of gypsum (powder): 180*1.42 = 256 grams

Water weight: 256*0.3 or (0.33) = 77 or (85) grams

For a quicker estimate of material consumption, we encourage you to use our calculator available at:

APPLICATION

A-STONE is an eco-friendly acrylic casting resin that is solvent-free, odourless and water-based. It is used to produce replicas, figurines, architectural elements, prototypes, models and decorations. This resin is weather and UV resistant.

For elements that are exposed to intensive contact with moisture, such as rainfall, such as external stucco elements, garden figures, etc., it is advisable to protect the castings from water ingress by impregnating them with E-CUPSTONE Impregnate.

In the A-STONE system it is possible to modify the properties, appearance, texture and tactile feel by adding various fillers such as quartz, sands, rock powders, metal powders, dyes and pigments. It is important that the fillers are dry before adding them to the A-STONE system. Sometimes it may be necessary to dry the fillers. The use of dyes from outside the A-STONE system should be avoided, as dyes of unknown origin may contain too much water or other additives that may interfere with the crosslinking process or limit the processability of the A-STONE system.

A-STONE covers and adheres perfectly to polystyrene foam and other foams. This makes it possible to produce lightweight portable elements that can be used, for example, in scenery or trade fair exhibitions. Through the use of several layers of four-way fabric A-STONE 150-4D very robust structures with strong mechanical and surface strength can be obtained.

A-STONE can be processed by a variety of methods, such as casting, rotational moulding, lamination and spraying. This allows the product to be adapted to a variety of production processes and applications.

PROCESSING TECHNOLOGY

1. Weigh the two components, component A (resin) and component B (hardener), in the correct proportions. Then pour the powder into the resin, i.e. add the filler, as described, in portions, stirring all the time. It is recommended to use E-CUPSTONE GYPSUM BLENDERS. Mixing by hand may not be sufficient, so a drill with a high-speed mixer is recommended. The mixing speed should be around 700 revolutions per minute to create a vortex and break up the fine lumps.

The mixing procedure should proceed as follows:

a) Mix the liquids, i.e. component A (resin) and pigments, for 15 to 30 seconds.

(b) Continue mixing, slowly adding the powder (Component B) to the liquid.

(c) Continue mixing until all the lumps are broken up and the consistency becomes creamy.

(d) Allow the mixture to stand for a while to remove air bubbles. If the mixture is too aerated, it may be necessary to use a vacuum chamber to remove air bubbles. The absence of air bubbles is important to obtain the correct cross-sectional structure of the casting and the surface texture.

(e) It is not recommended to process A-STONE at temperatures below 10°C.

Please note that exact proportions and mixing times may vary depending on the specific A-STONE product. It is always worth consulting the manufacturer's instructions for best results.

2 Once you have mixed the two ingredients and poured the mould with A-STONE, you will notice a minimal rise in temperature and a fairly rapid thickening of the mixture. It is worth remembering that A-STONE is a system that cures quickly, so you don't have a lot of time for operations. If you want to extend your working time, you can use retarder from e-cupstone, ranging from 0.5% to a maximum of 5%. The use of retarder can increase the working time from 8-15 minutes to as much as 100 minutes. However, excessive amounts of this additive should be avoided, and it should be remembered that the operating time also depends on ambient conditions such as temperature and humidity.

3 The time taken to unmould castings depends on their size, but practically, once the casting has had time to cool sufficiently, it can be removed from the mould. This process usually takes between 40 minutes and 1.5 hours.

The nature of the mould-side casting surface largely depends on the type of mould surface. For example, if the silicone mould has a glossy surface, the casting from A-STONE will also have a glossy surface. Conversely, if the silicone mould has a matt surface, the casting will be matt. Because the powder hardener is also a mineral filler, the character of the casting surface resembles natural stone or gypsum. This is why acrylic systems such as A-STONE are often referred to as polymer gypsum, polymer stone or polymer concrete. 

STORAGE

For A-STONE, the recommended storage temperature is usually between 10°C and 22°C. This is the temperature range that ensures the stability and quality of the material. The temperature should be controlled to avoid extreme conditions, such as excessive heat, which can affect the properties and durability of A-STONE.

HEALTH AND SAFETY

1. Personal protection: To ensure safety when working with A-STONE, appropriate personal protective equipment is recommended. Wear protective clothing, latex or vinyl gloves and safety goggles. This will help minimise the risk of contact with the chemical.
2. Avoiding contact with food and children: store uncured A-STONE materials away from foodstuffs and out of the reach of children. This protects both foodstuffs and children from exposure to the chemical.
3. Proper ventilation: A-STONE processing should be carried out in well-ventilated areas. Access to fresh air ensures adequate dispersion of any volatile chemicals, which helps to maintain safe working conditions.
4. Personal hygiene: After completing A-STONE operations, it is important to wash your hands thoroughly with soap in warm water. They can then be dried with a disposable paper towel. This is important to remove any residual substances from the hands and to ensure hygiene.

Please note that the information provided is general and refers to safety rules when handling chemicals. It is always important to follow the manufacturer's instructions and to familiarise yourself with the specific precautions and procedures for handling A-STONE provided by the product manufacturer.

If you have any doubts or questions about the processing technique or application of A-STONE, we recommend that you consult directly with the manufacturer or product supplier, who will provide accurate and up-to-date information on the subject.

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