Fiber Optic Concrete Sample

6stringmason

Well I got my first fiber optic sample just about done. I took it out of the mold and did some grinding on it. I have to wait a few days before I can really polish it up and seal it.

I sprayed it down with water to show what it will look like after its been sealed and waxed. Or pretty darn close anyway.

For some added flare I bought some paua shell rims, threw in a bag, and took a hammer to them. Then I took all the chunks, flakes, and dust, and threw it in the mold. You can see some of the stand out pretty good. It looks alot better in person. My camera didnt pick up alot of the little paua flakes that are scatter across the top.

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920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

Toothpick

Looks Cool !

concretemasonry

A couple of questions -

Are the optic fibers directly in contact with the concrete itself?

What are the fibers made of?

About 30 years ago, Owns Corning worked to develop a surface bonding masonry system using their glass fibers in a plaster/stucco mix the was applied to the dry stacked block wall. They discovered after a few years that the glass deteriorated over time and they had to change the fibers over to a special alkalai resistant glass to maintain integrity.

They started using ordinary fiberglass fibers (like in insulation, I suppose), but had to change.

I just mention this since it surprised me at the time. I have no idea of what your fibers look like.

If the fibers are the right material or not in direct contact, there probably is no problem.

Dick

Tscarborough

That is pretty sweet. Give me a cost, please, as I could see doing this in a stucco wall, too.

6stringmason

Sent ya a PM Tscar.


As far as the FO cable, its just standard glass cable. It came with different sizes of cable bundled up in a jacket. I just stripped the jacket and placed the FO cable randomly.

I havent heard of any ill effects of concrete on glass. I guess I would have to do some research, but I dont see how it would deteriote it. They are in direct contact with the crete itself. Its solid glass fiber, and the top is not exposed to the elements. Thanks for the heads up though.

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Kamps Masonry & Concrete Countertop Design Green Bay, WI
920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

Tscarborough

ConcreteMasonry, the issues that you address were structural. Since this is not structural, I don't think it would be an issue, for the first 50 or 100 years anyway.

Teetorbilt

6, I remember some previous questions about forming and molding. How did you end up doing it?

Looks really good BTW!

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Cole

Looks fantastic!!!

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concretemasonry

6stringmason -

You may want to check on the properties of the fibers if they are incontact with concrete. The alkalais in concrete erode the normal glass fibers over time and could cut off the light transmission.

The original problem was an embarassment to the fiber supplier and was discovered during structural testing after some problems.

The concrete can erode and sever the fibers depending on the diameter and type of glass. This occurred in a year or two. The alkalai-resistant fibers now used in concrete are different than the normal fiberglass fibers and have a longer life span.

Tsacarborough, one of the first problems was found south of you in San Antonio. A friend of mine had a problem with buildings he sold blockto. Other areas (Ohio and New England) had similar problems, so structural tests were run, revealing the incompatibility of materials.

As a short term solution, the fiber supplier had to import alkalai-resistant fibers from England(?). Subsequently, the actual Block Bond production was sold off to several regional bagging companies.

6stringmason, since the fiber optical installation in concrete may not have been contemplated by the fiber suppliers, it might be a good idea to make sure the fibers won't be erroded in your application.

Dick

Tscarborough

I am famiilar with the issue, and was surprised enough by the chemistry to read up on it.

6stringmason

I took a 1/16" bit and random drilled holes about 1/2" deep. Then I took some silicone and put a dab over each hole, and put the cables into those holes. I held them for a bit until the silicone set up enough to hold them on their own. Last step was wiping up the mess in the bottom of the mold with some acetone and toweling.

If anyone has any links to articles or site pertaining to the erosion of fiber optic glass in concrete could you please post them.

Also, I personally called the place I bought them since this was my first time dealing with fiber optics of any sort. The person I spoke to told me the ones to buy and had said thats what they're selling to alot of concrete countertop fabricators.

Now I dont know if they are putting them in direct contact as well, or using a sleeve of some sorts, but I would definitely like to read up on it. The though of the concrete reacting to the cable never crossed my mind.

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Kamps Masonry & Concrete Countertop Design Green Bay, WI
920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

Teetorbilt

To the best of my knowledge, glass is pretty much inert. I guess that's why they use it for test tubes, beakers and storage bottles in labs.

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You can't solve you're problems with the same level of thinking that created the problems.

Albert Einstein

6stringmason

Thats what I assumed. After all, fiber optics is just light traveling through a solid glass tube.

__________________
Kamps Masonry & Concrete Countertop Design Green Bay, WI
920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

calypso

That's hot sixstring! I heard about using it in concrete walls but I never tried it in concrete counters. I made a wood sculpture once that had sections of black painted plywood that were hollow. I drilled 1/4" holes through those sections and pushed 1/4" hollow plastic tubes through the holes leaving a few inches dangling inside to pick up the light of a bulb placed inside. It wasn't fiber optic cable but since the 1/4" tubes were only a few inches long the light of a bulb placed inside the sculpture transfered well. If you end up having trouble with the optics cable maybe plexiglass rod or a treated glass rod will work since you don't have to get the light to travel that far.

K2

Looks great six. I'm curious about the lamps. How many tubes can you run off of one lamp? Are they metal halide lamps and what is the replacement cost of the lamps? Or any specs on the FO unit/light generator?

6stringmason

Thanks guys.

K2eoj I just buy a illuminator from a company that deals with Fiber Optics. They have all sorts of different kinds for different applications. You can get single color wheels, or multiple color wheels that can rotate or be stopped on a certain color.

The number of cable you run off the illuminator is dependant upon the thickness of the cable youre running. You could easily run all your cable for a single countertop off one illuminator/light source.

Here's a link with some specs:
http://www.fiberopticproducts.com/Lightunits.htm

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Kamps Masonry & Concrete Countertop Design Green Bay, WI
920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

K2

Nice. Thanks!!

PrecisionFloors

Very nice work 6string. I have been thinking about looking into concrete counter tops as an addition to floorcovering. How much did it cost you to get set up and did you attend any manufacturer training?

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6stringmason

No training. Just lots and lots of reading and trial and error. Plus previous knowledge of concrete was beneficial.

The start up cost was considerable. In my eyes anyway. Thank God I already had a mixer.

I would say if you have a shop already, you could get set up for about $4-5k. Thats including mixer, grinder, diamond pads, and some misc. hand tools need for concrete work. Then you need to invest some in materials and start practicing.

__________________
Kamps Masonry & Concrete Countertop Design Green Bay, WI
920-680-3195
Visit our website @
http://www.concretecountertopsdesign.com/

PrecisionFloors

^^Thanks for the info. Forgive a stupid question, what material do you normally use for your forms? Also, have you looked into any light weight products as a substitute for normal concrete? Had a thought about using some of the self-leveling products used for decorative flooring, like Ardex SD-T....it is 6100psi compressive strength. What do you think?

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(772) 237-9900
Tile, Hardwood, Laminate, and Resilient
Installation, Sales & Repair - "We do it right the FIRST time"