casting Polymerbeton

>>Epoxy Resin is irritant an dangerous for the environment, be careful<<

here is the major filling compound:

fine, medium and coarse grained sand

the different sand mixed together shouldn't left any space between the grains

the ideal mixing ratio depends highly on the filling compounds

there are also ready to use commercial products available

a good mix of filling compounds can be glued together by about 8-10% epoxy resin

start with mixtures 30% fine sand 30% medium sand 30% coarse grained sand and 10% resin

you will have to cast a few testpieces before getting good results

filling plastic tubes is good for testcasts

casting:

first you have to build a form,
    remember to coat all surfaces with a layer of seperation material like bee wax
    otherwise you won't be able to get your cast out of the form

prepare the right amount and mixture of sand for your form

mix your resin and give it together with the sand

now everything seems dry and lumpy, keep mixing untill you get a homogen mush

fill in layer after layer in your form

between the layers you have to mechanical compress the mush to avoid air inclusions
with e.g. wooden sticks

good luck!

here is my first castresult, I'm quiet happy with it

seperation layer worked very good - only a little part of the form got broken

the cast wasn't compressed enough - and I used too less resin (about 0,5%)

too less material got in the mounting straps

leveling out a bit with filler

 and sprayed

a much better way to cast would be on an vibrating table:
the homogen mush would get viscous like water - right frequence is very important!
air inclusions would rise to the surface and all sand would perfectly slide together by gravity