HOW TO CARE FOR AND USE YOUR ALDAX GARDEN MOULDS

WHAT ARE ALDAX GARDEN MOULDS MADE FROM?

All our garden moulds are vacuum formed from High Impact Virgin ABS Plastic. This is the finest plastic for use with concrete. We use two coloured plastics, black and white ABS, both with a haircell design on the back of the mould. The thickness varies according to the mould size and desired end use.

For the DIY gardener wanting a limited number of castings at an economical price we provide moulds made from 1 and 2mm ABS. For the manufacturer we use 3 and 4mm ABS for additional strength and long service.

WHAT SIZE MOULDS ARE MADE?

We provide stock paver moulds with a diameter of 300, 400 and 600mm The depth varies from 2.5mm 3.75mm to 5mm. Mould sizes may vary slightly from the stated dimensions.

DO YOU MAKE CUSTOM MOULDS?

Yes, we are happy to quote for custom moulds of any size.

HOW MUCH USE CAN YOU EXPECT FROM ALDAX MOULDS?

Your 1 and 2mm moulds should give you 10 to 20 pours, even more if you are careful in your handling.

All moulds will have a much longer life if supported. This particularly applies to the professional heavy duty moulds subject to daily stress.

The rim of all moulds takes the most strain. Even on the lighter weight moulds you can expect much longer life if you reinforce the mould edges and area underneath the mould where the cavity meets the flat rim area with duct tape. This is the area most prone to splitting in the event of incorrect handling.

The heavy duty moulds should be supported with timber framing. To get maximum life from these moulds it is essential that the strain of supporting the weight of the heavy concrete be taken off the moulds themselves with this type of additional back up support.Care in this area will effectively double the life of the moulds.

The simple frames can be made from 5mm DAR pine timber with a 1.25mm plywood base. Drill 3mm holes at intervals in the rim of the mould and nail or screw the mould in the frame making sure that the base of the mould is resting firmly on the plywood base.

WHAT TYPE OF RELEASE AGENT SHOULD I USE?

For those used to using metal or aluminium garden moulds, we have to issue a special warning! DO NOT USE MACHINE OIL OR OTHER PETROLEUM BASED OILS ON PLASTIC MOULDS. This will cause deterioration in the plastic and ultimate destruction. Use only vegetable oils, such as Castor Oil, which may be dissolved in Methylated Spirits for spray on application.

HOW TO RELEASE AIR BUBBLES

To avoid adding unecessary strain to your plastic concrete mould do not lift it when filled with concrete and tap it on a bench, as you would do with a hobby mould filled with plaster. The considerable weight of a concrete filled mould is enough to crack it when used in this fashion.

If you have not mounted your mould in a wooden back -up simply place a board under the mould before pouring and vibrate the board by tapping. This method places no stress on either you or your mould.

Professional casters are advised to use vibrating tables.

MOVING MOULDS WHEN FILLED WITH CONCRETE.

Lifting moulds filled with concrete seriously weakens the plastic rim, so simply slide a wooden plywood board under the mould to take the weight and to make moving much easier.

CAN I COLOUR THE CONCRETE?

Concrete is easily coloured by adding metallic iron oxides to the concrete mix before pouring. 10 to 20 ml of oxide pigment is usually sufficient for a paver. The colour is pale when wet and intensifies as it dries.

Before doing large batch pours, do a trial casting and allow the sample to dry to avoid having your pavers darker or lighter than you intended. Best of all iron oxides are UV stable. And do not require sealers.

WHAT CONCRETE MIX SHOULD I USE?

For garden moulds requiring strength such as steps, garden seats, tables or foundations a STRUCTURAL CONCRETE is required. This is what we generally call concrete in building terminology. To make structural concrete, mix:

1 part Portlane Cement

2 parts Sand

3 parts gravel

water to suit.

These quantities are by volume. For instance 1 shovel of cement 2 shovels of sand and 3 shovels of gravel. After mixing the dry ingredients togethercommence adding water a little at a time until the mix is just pourable.

For the decorative concrete moulds that do not need to be as strong as steps etc you can use an ORNAMENTAL CEMENT mix consisting of:

1 part of Portland cement

3 parts sand

concrete pigments if desired

water to suit

All measured by volume as previously. This mix does not need to be as strong as Structural Concrete and usually is more fluid, to pour into the moulds easily and give a good surface.

For pavers the mix can be anywhere between the structural and the ornamental. As they need reasonable strength and at the same time need to be decorative. We normally use 1 part cement, 2 parts sand and 1 part gravel. Vary this mix to achieve the effect you are looking for. Use small pea gravel rather than blue metal or similar.

For a more complete understanding of mixing,decorating and setting up a business for making garden ornaments we have prepared a book called “How to turn Concrete into Gold”available from our web site

For those who would like to learn how to make latex moulds to manufacture garden ornaments we have completed a fully illustrated book showing our factory methods for making a wide variety of different moulds entitled “How to make Latex moulds” see our web site