Using Ciment Fondu: A Comprehensive Guide To Application

Ciment Fondu is a versatile and resistant product that can be used alone or mixed with other materials. It is a hydraulic binder obtained by cooking and then milling a mix of limestone and clay. It has a wide range of applications, including construction, industrial, and high-temperature uses. When used as a hydraulic binder base for speciality concretes or on its own, Ciment Fondu exhibits excellent resistance to heat, thermal cycles, and abrasion. It is also chemically resistant to acid corrosion and other aggressive substances due to its ability to not release lime during hydration, which sets it apart from Portland cement.

Sculpting with ciment fondu

Ciment Fondu is a popular material for sculptors due to its extreme hardness, quick-setting properties, and ability to produce superb detail. It is a versatile material that can be used for both casting and sculpting and is ideal for large outdoor projects. Here are some tips and instructions for sculpting with Ciment Fondu:

Preparing the Ciment Fondu Mix

Ciment Fondu is a fine high alumina casting cement that achieves its full strength in 24 hours and has a working time of approximately 2 hours. When preparing the mix, always wear gloves and other appropriate protective gear as the material is very alkaline and can cause burns. For small sculptures or those that will be kept indoors, you can mix Ciment Fondu powder with water to create a creamy slurry. If you're using it outdoors, combine 2 parts fine silica sand with 1 part Ciment Fondu powder, adding enough water to allow for brush application.

Working with Moulds

When working with moulds, it's best to work on one section at a time. Start by applying the slurry to the mould with a brush, ensuring you work it into all the details and coat the surface evenly to a thickness of about 1.5mm. Remember to coat your mould with soft soap liquid before you begin and keep it damp.

Reinforcing the Sculpture

To reinforce your sculpture, create more fondue slurry without sand. Paint this slurry onto the layer of pressed ciment. Then, take a piece of fibre glass mat, dip it into the slurry, and rub it between your fingers to work it into the fibres. Lay the fibreglass in the mould, continuing with small pieces until the entire mould surface is covered.

Final Steps

Brush on another layer of slurry to ensure all the fibre glass is lying flat and even. Then, press a final layer of stiff ciment fondu mix to achieve a total thickness of about 13mm. Firmly tamp it down and clean the edges of the mould. Leave the sculpture under a wet cloth to cure for 24 hours.

Ciment Fondu sets through curing rather than drying, so it must be kept wet until it hardens completely. Drying out can prevent proper setting, resulting in a weak and crumbly final product.

Additional Tips

• Ciment Fondu is suitable for high-temperature applications when combined with appropriate refractory aggregates. It can withstand temperatures up to 1250°C, making it ideal for projects like outdoor ovens.
• When used with suitable aggregates, Ciment Fondu can be used for concrete insulation in refractory applications.
• In formulated products for building chemistry, Ciment Fondu serves as a reagent or main binder for products like fast-setting mortar, tile adhesive, and self-levelling products.
• Ciment Fondu can be used as an accelerator for Portland cements in rapid-sealing work and minor repairs. However, mixtures of Ciment Fondu and Portland cement must not be used for structural purposes.
• When mixing Ciment Fondu with regular cement, be aware that it will lose its temperature resistance characteristics.
• For concrete work in cold temperatures, Ciment Fondu can be used at temperatures as low as -10°C. Protect the concrete surface from freezing in the first few hours.
• Ciment Fondu does not have a Health Compliance Certificate (HCC) for projects involving foodstuffs or potable water.

Ciment fondu for outdoor ovens

Ciment fondu is a versatile and resistant hydraulic binder that can be used for outdoor ovens. It is made by cooking and then milling limestone and clay mixtures. When used with refractory aggregates, such as firebrick grog, Ciment fondu mortars and concretes can withstand temperatures up to 1250°C.

To build an outdoor pizza oven, you will need to use refractory materials that can withstand the extreme heat of up to 1,200°C. These include firebrick grog, perlite, vermiculite, fireclay, and high alumina cement. Ciment fondu can be used as a suitable replacement for high alumina cement.

The recommended mix of firebrick grog and ciment fondu is 4 parts grog to 1 part cement. The ingredients should be mixed in the following order: 80% of the prepared water, coarse grog, ciment fondu, fine grog, and then the remaining water to achieve a plastic consistency. For the best performance, the concrete should be compacted by rodding or vibration.

It is important to note that alumina cement, including ciment fondu, can be harmful to human health. It is advised to wear personal protective equipment (PPE) when handling this product, as it can cause respiratory issues and skin irritation.

Ciment fondu for industrial applications

Ciment Fondu is a versatile product with many industrial applications. Its unique properties make it suitable for use in various sectors, including construction, mining, and heavy civil grouting.

One of its primary applications is as a hydraulic binder base for refractory and specialty concrete. Its excellent mechanical strength makes it ideal for use in mortars and concretes, especially in refractory applications where temperatures can reach up to 1250°C. When used in combination with suitable aggregates, Ciment Fondu can withstand even higher temperatures of up to 1,750°C. This makes it perfect for constructing industrial furnaces, ovens, and incinerators.

In the construction industry, Ciment Fondu is used as a reagent in formulated products and as an accelerator for Portland cements in rapid-sealing work and minor repairs. It is also used in building chemistry, serving as the main binder for products like fast-setting mortar, tile adhesive, and self-levelling compounds.

In mining and heavy civil grouting, Ciment Fondu is invaluable for setting drill casings and grout standpipes due to its rapid hardening capabilities, reducing delay times before re-drilling. It can also be used to seal fractured ground conditions and set instrumentation or rock anchors.

Additionally, Ciment Fondu is an excellent choice for projects requiring resistance to corrosion and abrasion. Its chemical composition gives it superior resistance to acid corrosion and a wide range of aggressive substances, making it ideal for use in sewage and wastewater systems, as well as in seaside and agricultural projects.

With its fast setting time, high-temperature resistance, and excellent mechanical strength, Ciment Fondu is a versatile and reliable product for a wide range of industrial applications.

Ciment fondu for concrete insulation

Ciment Fondu is a versatile and resistant product that can be used alone or mixed with other materials. It is a pioneer in aluminate cements, providing excellent resistance to heat, thermal cycles, and abrasion. When used for concrete insulation, Ciment Fondu offers numerous benefits and applications.

One of its key advantages is its ability to withstand high temperatures. When combined with suitable aggregates, Ciment Fondu can resist temperatures ranging from -180°C to 1250°C. This makes it ideal for use in fireplace and chimney construction, foundry floors, and metallurgical works. The concrete mix should be compacted by rodding or vibration to ensure optimal performance. Additionally, Ciment Fondu-based concrete and mortars must be kept damp for the first 24 hours after setting to prevent rapid heat evolution during the hardening process.

Ciment Fondu is also suitable for outdoor projects, especially decorative wall surfaces. When combined with stone aggregates, it offers a cost-effective and durable solution, allowing sculptors and builders to create large-scale works with great freedom of design. The concrete mix can be reinforced to suit specific needs, making it a versatile option for various projects.

In terms of preparation, Ciment Fondu should be mixed with aggregates as a single binder. The recommended quantity for concrete work is 400 kg/m3 of cement, with a water-to-cement ratio of a maximum of 0.40. It is important to wear protective equipment, such as gloves and PPE, when working with Ciment Fondu due to its high alkalinity.

Ciment Fondu has a quick setting time, usually taking 4 to 5 hours to harden and achieving its full strength within 24 hours. This makes it a convenient choice for projects that require a quick turnaround, such as sealing masonry or plumbing elements.

Ciment fondu for sewer pipes

Ciment fondu is a high alumina cement that is ideal for casting and sculpting. It is widely used by sculptors because it is extremely hard and quick-setting, giving superb detail. It is also suitable for high-temperature applications when used with appropriate refractory aggregates.

When used with the correct aggregates, ciment fondu can be used to create sewer pipes that can withstand temperatures of up to 1,250° C. The process of creating sewer pipes using ciment fondu is similar to that of creating sculptures or other castings.

First, a mould is created that is the inverse of the desired pipe shape. This mould is then coated with a soft soap liquid and kept damp.

Next, a mixture of ciment fondu and aggregate is created. The specific aggregate used will depend on the expected temperatures and conditions that the sewer pipe will be subjected to. For high-temperature applications, a refractory or heat-resistant aggregate such as firebrick grog or vermiculite is used. This mixture is then worked into the mould in layers, ensuring that all details are filled and that the thickness is even.

After the mould is filled, it is reinforced with a layer of fibre glass mat. This helps to strengthen the cast and prevent cracking.

Finally, the mould is left to cure for 24 hours. It is important that the ciment fondu is kept wet during this time, as drying out can prevent proper setting and leave the final product weak and crumbly.

Once the curing process is complete, the mould can be removed, revealing the finished sewer pipe.

Frequently asked questions