CONCRETE ARTISAN
EXPERIENCE MATTERS!
Todays artisan is a highly skilled professional craftsman that has honed his or her skills over several years in order to manipulate complex mix designs to achieve desired results. In order to push the boundaries you must be willing to fail more times then you succeed. We at Rockit systems along with our strategic partners have several decades of experience utilizing and implementing out of the box approaches to create what many thought could not be done. With ever changing technologies we stay focus on the now while relying on our past in the pursuit to bring our very best. Here are a few of the processes we use to do that...
UHPC
THE HOLY GRAIL OF CONCRETE
Ultra High Performance Concrete is a nano-ceramic cement that is inherently self-structural, corrosion-proof, fireproof, mold and mildew-proof. It is highly resistant to shrinkage, creep and corrosion, while able to self-heal micro-cracking and endure time with a life span of thousands of years. UHPC eliminates 90% of the problems associated with regular concrete. UHPC is a material with immense possibilities. Industrial applications of UHPC are becoming common in some of most hostile environments in the world.
MOLD MAKING
CREATING TEXTURES
We start with a picture or sketch, even one on a napkin will work. The design is then created using computer aided design (CAD) software. The artwork is then uploaded into computer aided manufacturing software (CAM) which creates tool paths allowing a computer numerical control (CNC) mill to carve the design into a sheet of Medium Density Fiber Board (MDF). The milled carving is then post processed and is now ready to create a final impression. Polyurethane rubber is carefully casted onto the sheet which when dried creates a thin rubber negative known as a FORMLINER. This liner will now be used to produce unique textures during the production process.
TECHNIQUES
ADDING COLOR
There are several ways to add color to concrete depending on the desired look you are trying to achieve. With almost all of our products we start by adding a base color using dry pigment powders that are used integrally in the concrete to create a range of colors. The advantage of using Pigments is the color in consistent all the way through the product. Once the concrete has been demolded additional colors and effects such as Sand blasting and Acid etching are commonly used.
CASTING TECHNIQUES
There are lots of methods used to create textures other than the use of formliners. You can spray, pour, hand pack even use fabric. In fact many times all of them can be used on a single piece to create a desired look. There is no right or wrong way, it all comes down to the artisan and what works best for them. Many guys use simple tricks such as baking soda and other retarders to create some pretty wild effects. If your going for an exposed aggregate look then sky's the limit, virtually anything can be added. Sea shells, bottle caps, Glass and Rocks are all very common.
APPLYING COATINGS
When it comes to applying our coatings, we take every step possible to insure optimal results. Most of our coatings are sprayed in a clean room setting. Unlike traditional sealers our Nano coatings are extremely thin and can be built up in layers to achieve a desired sheen. Since our coatings are crystal clear it allows us the unique ability to tint them ever so slightly using pure pigments. This technique creates a transparent finish with just a subtle hint of color that can only be seen in certain lighting conditions.
MACHINERY
WATERJET CUTTING
Although all of our panels are extremely easy to cut onsite using traditional tools, there are times we need the help of computers. Utilizing CNC Waterjets and routers we are able to cut extremely complex shapes when needed. This also works great when a jobsite is filled with obstacles that will require lots of manual cutting. We can shape them to fit like a puzzle before they are shipped. This will save lots of time and labor when installed.
HYDRAULIC PRESS
When we have a project that require extreme detail we rely on a 50 Ton Hydraulic Press to get the job done. There are times when we need to glue panels together in order to create a custom profile. In order to assure proper adhesion there must be equal amounts of pressure throughout the boards that are being fused
VACUUM PRESS
Sometime we will use a vacuum press to glue flat panels, they are not as quick and efficient as the hydraulic press. On the other hand for laminating 3d objects or making quick intricate molds there is nothing more efficient then a vacuum. There are times we need to form solid materials into bent object and for that it's our go to.