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Replacing Crumbling Stonework at a University in Australia

PROJECT: Make molds to replace crumbling stonework at a university in Australia.
PROBLEM: Project deadline is quickly approaching.
ANSWER: Use Smooth-On's EZ-Spray® Jr. system and EZ-Spray® Silicone 35 rubber.

Adelaide University's Bonython Hall in South Australia was in need of renovation. As part of the project, two domes at the back of the building had to be replaced due to the deterioration of the stone work. It was decided that an eight-section mold of one of the domes would be created. This mold could then be used for the recasting, in glass reinforced concrete, of both domes.

Russell Brown from Rubber Impressions was contracted to make the molds. After seeing a demo of Smooth-On's EZ-Spray Jr. system, Brown decided to make the dome molds from EZ-Spray Silicone backed with a mother mold of fiberglass.

The domes consisted of eight segments, each 2.6m high and 1.1m wide at the base, which were shimmed and sealed with Smooth-On's Super Seal®. Each section took about 6 hours to spray. Following the application of EZ-Spray Silicone, each section was then given a smooth coat of Smooth-Sil® 930 thickened with Thi-Vex® to fill any holes or unevenness on the surface of the EZ-Spray Silicone. This also helped prevent any mechanical lock on of the fiberglass support jacket.

Brown estimated that had he used a brushable polyurethane rubber each individual panel would have taken three days to mold. The EZ-Spray Jr. system saved him more than two weeks time and thousands of dollars in labor costs.
 Bonython Hall on the campus of Adelaide University in South Australia

1 - Bonython Hall on the campus of Adelaide University in South Australia
 One of the eight-sided domes being prepared for the mold making process.

2 - One of the eight-sided domes being prepared for the mold making process.
 Parting shims were created from clay and wood to segment the dome. Smooth-On's Super Seal® was used to seal the stone surface and shims.

3 - Parting shims were created from clay and wood to segment the dome. Smooth-On's Super Seal® was used to seal the stone surface and shims.
 Smooth-On's EZ-Spray® silicone is sprayed in layers over the original

4 - Smooth-On's EZ-Spray® silicone is sprayed in layers over the original
 The EZ-Spray® Jr. gun is highly maneuverable allowing mold rubber to be applied to undercuts and hard to reach areas.

5 - The EZ-Spray® Jr. gun is highly maneuverable allowing mold rubber to be applied to undercuts and hard to reach areas.
 Typically 4 layers are sprayed to an ultimate thickness of 3/8'' (1cm).

6 - Typically 4 layers are sprayed to an ultimate thickness of 3/8'' (1cm).
 Smooth-Sil® 930 is thickened with Thi-Vex® thickening agent.  Thickened rubber is used to fill deep undercuts to prevent mechanical lock between the support shell and the original model.

7 - Smooth-Sil® 930 is thickened with Thi-Vex® thickening agent. Thickened rubber is used to fill deep undercuts to prevent mechanical lock between the support shell and the original model.
 The process is repeated as sections are completed one at a time.

8 - The process is repeated as sections are completed one at a time.
 Mold making in progress

9 - Mold making in progress
 Once the mold rubber has full cured, support shell segments are created using fiberglass and resin.

10 - Once the mold rubber has full cured, support shell segments are created using fiberglass and resin.
 Shell is built in eight pieces with supports embedded for better structure

11 - Shell is built in eight pieces with supports embedded for better structure
 Once the support shell has fully cured, sections are removed exposing the cured rubber mold.

12 - Once the support shell has fully cured, sections are removed exposing the cured rubber mold.
 E-Z Spray® silicone is flexible and can be peeled back from the original

13 - E-Z Spray® silicone is flexible and can be peeled back from the original
 Silicone has good tear strength.

14 - Silicone has good tear strength.
 Rubber mold segments are then seated into their respective support shells.

15 - Rubber mold segments are then seated into their respective support shells.
 Mold segments are readied for transport to Rubber Impressions' casting facility.

16 - Mold segments are readied for transport to Rubber Impressions' casting facility.
 At the casting facility, mold sections will be re-assembled

17 - At the casting facility, mold sections will be re-assembled
 EZ-Spray® sections ready for assembly and GFRC casting

18 - EZ-Spray® sections ready for assembly and GFRC casting

                   
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