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workshops:prototypes:breezeblocks [2023/04/15 11:14]
Michael Byrne ↷ Page moved from workshops:prototypes:breezeblocks to workshops:prototypes:2022-23delivery-lasercutcovers:breezeblocks 		workshops:prototypes:breezeblocks [2023/06/01 20:45]
Michelle Brown ↷ Page moved from workshops:prototypes:2022-23delivery-lasercutcovers:breezeblocks to workshops:prototypes:breezeblocks
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 ====== Breeze Blocks ===== ====== Breeze Blocks =====
  
-{{:workshops:prototypes:6169-1160-0007.jpg?400|}}+{{workshops:prototypes:2022-23delivery-lasercutcovers:6169-1160-0007.jpg?400|}}
  
 Concept by Courtney Ingle, developed by Steve Curran, 2022  Concept by Courtney Ingle, developed by Steve Curran, 2022 
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 ===== Background =====  ===== Background ===== 
  
-{{:workshops:prototypes:bbw_breeze_block_render.jpg?700|}}+{{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_breeze_block_render.jpg?700|}}
  
 Breezeblocks have historically been made from concrete, clay, or mud. They have been popular in tropical and subtropical climates where a combination of ventilation and privacy are valued. Breezeblocks have appeared in Brisbane architecture over the decades. A search of the 61,000 images comprising the Frank and Eunice Corley Collection Corley Explorer (slq.qld.gov.au) held by the SLQ returns a total of 387 images tagged with the term ‘Breezeblocks’. The photographs were taken by the Corleys all around Queensland during the 1960s–70s.  Breezeblocks have historically been made from concrete, clay, or mud. They have been popular in tropical and subtropical climates where a combination of ventilation and privacy are valued. Breezeblocks have appeared in Brisbane architecture over the decades. A search of the 61,000 images comprising the Frank and Eunice Corley Collection Corley Explorer (slq.qld.gov.au) held by the SLQ returns a total of 387 images tagged with the term ‘Breezeblocks’. The photographs were taken by the Corleys all around Queensland during the 1960s–70s. 
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 ====== Materials and Tools ====== ====== Materials and Tools ======
  
-^ {{:workshops:prototypes:bbw_formply_image.jpg?300}}  | Formply—an exterior-grade plywood faced on both sides with resin-impregnated paper. The smooth faces release easily from the cast concrete.  |                                                                                                                                                            ^ +^ {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_formply_image.jpg?300}}  | Formply—an exterior-grade plywood faced on both sides with resin-impregnated paper. The smooth faces release easily from the cast concrete.  |                                                                                                                                                            ^ 
-| {{:workshops:prototypes:bbw_metal_bracket_image.jpeg?300}}  | Metal brackets/screws—will be used to screw the Formply mould box together.                                                                                                                                                            | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_metal_bracket_image.jpeg?300}}  | Metal brackets/screws—will be used to screw the Formply mould box together.                                                                                                                                                            | 
-| {{:workshops:prototypes:bbw_10g_x_15mm_self_tapping_screws.jpeg?300}}  | 10G x 15mm Phillips Drive self-tapping screws—use with metal brackets to screw Formply mould box together. 10G is the diameter. The 15mm length ensures the screws do not poke through the inside of the 17mm Formply mould. While these are sheet metal screws, they work perfectly fine with plywood.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_10g_x_15mm_self_tapping_screws.jpeg?300}}  | 10G x 15mm Phillips Drive self-tapping screws—use with metal brackets to screw Formply mould box together. 10G is the diameter. The 15mm length ensures the screws do not poke through the inside of the 17mm Formply mould. While these are sheet metal screws, they work perfectly fine with plywood.  | 
-| {{:workshops:prototypes:bbw_phillips_screwdriver.jpg?direct&300}}  | Phillips screwdriver  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_phillips_screwdriver.jpg?direct&300}}  | Phillips screwdriver  | 
-| {{:workshops:prototypes:bbw_3mm_clear_acrylic_image.jpg?300}}  | 3mm clear acrylic sheet—you will use the laser to cut the profile of your breezeblock design in this material. The cut pieces will serve as templates both for cutting your XPS foam cores as well as accurately locating these cores within the mould cavity.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_3mm_clear_acrylic_image.jpg?300}}  | 3mm clear acrylic sheet—you will use the laser to cut the profile of your breezeblock design in this material. The cut pieces will serve as templates both for cutting your XPS foam cores as well as accurately locating these cores within the mould cavity.  | 
-| {{:workshops:prototypes:bbw_trotec_speedy_300_atmos_image.jpg?300}}  | Trotec Speedy 300 laser cutter/engraver and Atmos fume extractor—you will receive instruction in using this laser to cut the profile of your breezeblock design in acrylic sheet.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_trotec_speedy_300_atmos_image.jpg?300}}  | Trotec Speedy 300 laser cutter/engraver and Atmos fume extractor—you will receive instruction in using this laser to cut the profile of your breezeblock design in acrylic sheet.  | 
-| {{:workshops:prototypes:bbw_xps_foam_image.jpg?300}}  | Extruded polystyrene (XPS) foam—a high-density foam board supplied in 50mm thickness which can be stacked & glued to build thickness. This foam is easily cut using a hot wire. It will be used to make the inserts/cores which form the penetrations through your breezeblock.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_xps_foam_image.jpg?300}}  | Extruded polystyrene (XPS) foam—a high-density foam board supplied in 50mm thickness which can be stacked & glued to build thickness. This foam is easily cut using a hot wire. It will be used to make the inserts/cores which form the penetrations through your breezeblock.  | 
-| {{:workshops:prototypes:bbw_proxxon_thermocut_230-e_hot_wire_cutter_image.png?300}}  | Proxxon Thermocut 230/E Hot Wire Cutter—used for cutting extruded polystyrene (XPS) foam board.  |                                                                                                                                                                                                 | {{:workshops:prototypes:bbw_hwff_sculpting_tool.png?300}}  | Hot Wire Foam Factory Sculpting Tool Kit—used for cutting XPS foam to desired height. | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_proxxon_thermocut_230-e_hot_wire_cutter_image.png?300}}  | Proxxon Thermocut 230/E Hot Wire Cutter—used for cutting extruded polystyrene (XPS) foam board.  |                                                                                                                                                                                                 | {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_hwff_sculpting_tool.png?300}}  | Hot Wire Foam Factory Sculpting Tool Kit—used for cutting XPS foam to desired height. | 
-| {{:workshops:prototypes:bbw_hwff_foam_fusion.png?300}}  | Hot Wire Foam Factory Fusion Glue will be used for laminating the XPS foam cores, as this glue can be cut on the hot wire. This glue is water-based and non-toxic. Note that bonds can take a long time to fully dry—particularly in high humidity.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_hwff_foam_fusion.png?300}}  | Hot Wire Foam Factory Fusion Glue will be used for laminating the XPS foam cores, as this glue can be cut on the hot wire. This glue is water-based and non-toxic. Note that bonds can take a long time to fully dry—particularly in high humidity.  | 
-| {{:workshops:prototypes:bbw_double-sided_acrylic_craft_tape.jpeg?direct&400|}}  | Double-sided tape—used for affixing laser-cut acrylic templates to XPS foam prior to cutting foam on hot wire. A low-tack version is sufficient for this purpose.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_double-sided_acrylic_craft_tape.jpeg?direct&400|}}  | Double-sided tape—used for affixing laser-cut acrylic templates to XPS foam prior to cutting foam on hot wire. A low-tack version is sufficient for this purpose.  | 
-| {{:workshops:prototypes:bbw_festool_sanding_block.jpg?300}}  | Sanding block with dust extraction—used to smooth faces of XPS foam cores after they are cut on the hot wire.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_festool_sanding_block.jpg?300}}  | Sanding block with dust extraction—used to smooth faces of XPS foam cores after they are cut on the hot wire.  | 
-| {{:workshops:prototypes:bbw_hwff_bounce_image.jpg?direct&400|}}  | Hot Wire Foam Factory Bounce—a brush-on product that will strengthen and seal the XPS foam to protect it from the mould release agent. Best applied to horizontal surfaces to avoid slumping; otherwise, apply multiple, thin coats.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_hwff_bounce_image.jpg?direct&400|}}  | Hot Wire Foam Factory Bounce—a brush-on product that will strengthen and seal the XPS foam to protect it from the mould release agent. Best applied to horizontal surfaces to avoid slumping; otherwise, apply multiple, thin coats.  | 
-| {{:workshops:prototypes:bbw_acrylic_scoring_knife.jpg?300}}  | Acrylic scoring knife—used for scoring acrylic core locator in preparation for snapping it into manageable pieces for easier use when positioning XPS foam cores in mould cavity.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_acrylic_scoring_knife.jpg?300}}  | Acrylic scoring knife—used for scoring acrylic core locator in preparation for snapping it into manageable pieces for easier use when positioning XPS foam cores in mould cavity.  | 
-| {{:workshops:prototypes:bbw_cut_resistant_gloves.png?300}}  | Cut-resistant safety gloves—worn when scoring and snapping your acrylic core locator into pieces using edge of table.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_cut_resistant_gloves.png?300}}  | Cut-resistant safety gloves—worn when scoring and snapping your acrylic core locator into pieces using edge of table.  | 
-| {{:workshops:prototypes:bbw_uhu_expanded_polystyrene_glue_image.jpg?300}}  | UHU Expanding Polystyrene Glue will be used for adhering the underside of your XPS foam cores to the Formply mould box base. This contact adhesive can also be used for laminating XPS foam to itself.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_uhu_expanded_polystyrene_glue_image.jpg?300}}  | UHU Expanding Polystyrene Glue will be used for adhering the underside of your XPS foam cores to the Formply mould box base. This contact adhesive can also be used for laminating XPS foam to itself.  | 
-| {{:workshops:prototypes:bbw_foam_sealing_tape_image.png?300}}  | Single-sided self-adhesive foam tape—adhered to Formply edges where they butt together. This tape will ensure a mould is watertight, but is unnecessary if Formply components have been assembled with a close fit.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_foam_sealing_tape_image.png?300}}  | Single-sided self-adhesive foam tape—adhered to Formply edges where they butt together. This tape will ensure a mould is watertight, but is unnecessary if Formply components have been assembled with a close fit.  | 
-| {{:workshops:prototypes:bbw_vaseline_petroleum_jelly.jpg?300}}  | Petroleum jelly—mould release for thin application to XPS foam surfaces sealed by Bounce rubberiser.  Can also be applied to Formply, though usually not necessary.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_vaseline_petroleum_jelly.jpg?300}}  | Petroleum jelly—mould release for thin application to XPS foam surfaces sealed by Bounce rubberiser.  Can also be applied to Formply, though usually not necessary.  | 
-| {{:workshops:prototypes:bbw_dingo_fast_set_hi-strength_concrete_mix.jpg?300}}  | Concrete mix—a ready-to-use mixture of cement, sand, and aggregate (gravel). Just add water. Note that high-strength mixes typically feature a smaller aggregate size—which is better suited to casting breezeblocks.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_dingo_fast_set_hi-strength_concrete_mix.jpg?300}}  | Concrete mix—a ready-to-use mixture of cement, sand, and aggregate (gravel). Just add water. Note that high-strength mixes typically feature a smaller aggregate size—which is better suited to casting breezeblocks.  | 
-| {{:workshops:prototypes:bbw_3m_cool_flow_respirator.jpg?300}}  | P2/N95 respirator—the minimum level of respiratory protection advised to protect against inhalation of airborne dust generated when handling dry concrete mix.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_3m_cool_flow_respirator.jpg?300}}  | P2/N95 respirator—the minimum level of respiratory protection advised to protect against inhalation of airborne dust generated when handling dry concrete mix.  | 
-| {{:workshops:prototypes:bbw_nitrile_gauntlets.jpg?300}}  | Nitrile gauntlets—extended skin contact with the alkaline cement in concrete will result in chemical burns. A gauntlet that extends up the arm will protect your skin while also avoiding dirty water flowing into the glove when washing concrete from tools.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_nitrile_gauntlets.jpg?300}}  | Nitrile gauntlets—extended skin contact with the alkaline cement in concrete will result in chemical burns. A gauntlet that extends up the arm will protect your skin while also avoiding dirty water flowing into the glove when washing concrete from tools.  | 
-| {{:workshops:prototypes:bbw_protector_face_shield.png?300}}  | Face shield—there is a risk that water containing cement may splash before it is fully incorporated into the concrete during mixing. A face shield provides good protection, and unlike safety glasses or goggles can be worn together with prescription glasses.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_protector_face_shield.png?300}}  | Face shield—there is a risk that water containing cement may splash before it is fully incorporated into the concrete during mixing. A face shield provides good protection, and unlike safety glasses or goggles can be worn together with prescription glasses.  | 
-| {{:workshops:prototypes:bbw_15l_bucket.jpeg?300}}  | Plastic or rubber bucket—the preferred vessel for mixing small quantities of concrete.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_15l_bucket.jpeg?300}}  | Plastic or rubber bucket—the preferred vessel for mixing small quantities of concrete.  | 
-| {{:workshops:prototypes:bbw_velocity_measuring_cups.png?300}}  | Measuring cups—essential for accurately measuring how much water you add to your concrete mix. A 10 kg bag of mix requires 1-1.5 litres of clean water.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_velocity_measuring_cups.png?300}}  | Measuring cups—essential for accurately measuring how much water you add to your concrete mix. A 10 kg bag of mix requires 1-1.5 litres of clean water.  | 
-| {{:workshops:prototypes:bbw_hyde_margin_trowel.jpeg?300}}  | Margin trowel—used for mixing small quantities of concrete and water in a bucket. The squared end helps to ensure no dry mix remains at bottom of bucket.  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_hyde_margin_trowel.jpeg?300}}  | Margin trowel—used for mixing small quantities of concrete and water in a bucket. The squared end helps to ensure no dry mix remains at bottom of bucket.  | 
-| {{:workshops:prototypes:bbw_kango_gauging_trowel.jpeg?300}}  | Gauging trowel—used for picking up wet concrete from bucket and placing into your breezeblock mould. Gloved fingers are also a great tool for this ;-)  | +| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_kango_gauging_trowel.jpeg?300}}  | Gauging trowel—used for picking up wet concrete from bucket and placing into your breezeblock mould. Gloved fingers are also a great tool for this ;-)  | 
-| {{:workshops:prototypes:bbw_kango_355mm_concrete_trowel.png?300}}  | 335mm concrete smoothing trowel—used for leveling and smoothing concrete to top of mould box.  |+| {{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_kango_355mm_concrete_trowel.png?300}}  | 335mm concrete smoothing trowel—used for leveling and smoothing concrete to top of mould box.  |
  
  
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 All inside faces of the block will be formed against XPS foam inserts or cores. You will receive instruction on how to cut the foam using a hot wire. Because the XPS foam sheets are not readily available in a thickness corresponding to the full depth of a breezeblock, you will need to glue 2 or 3 thicknesses in a sandwich.  All inside faces of the block will be formed against XPS foam inserts or cores. You will receive instruction on how to cut the foam using a hot wire. Because the XPS foam sheets are not readily available in a thickness corresponding to the full depth of a breezeblock, you will need to glue 2 or 3 thicknesses in a sandwich. 
  
-{{:workshops:prototypes:bbw_breezeblock_mould_exploded_view_with_text.png?700|}}+{{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_breezeblock_mould_exploded_view_with_text.png?700|}}
  
 ====== Session One ====== ====== Session One ======
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 (explain what this is and how to search for breezeblocks)  (explain what this is and how to search for breezeblocks) 
  
-{{ :workshops:prototypes:breeze_blocks.pdf |}}+{{ workshops:prototypes:2022-23delivery-lasercutcovers:breeze_blocks.pdf |}}
  
 ====Overview==== ====Overview====
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   * All XPS foam cores adhered to either bottom panel or side panels (as appropriate) of mould boxes using UHU Polystyrene Glue    * All XPS foam cores adhered to either bottom panel or side panels (as appropriate) of mould boxes using UHU Polystyrene Glue 
  
-{{:workshops:prototypes:bbw_breezeblock_formply_cut_layout_screen_capture.png?600|}}+{{workshops:prototypes:2022-23delivery-lasercutcovers:bbw_breezeblock_formply_cut_layout_screen_capture.png?600|}}
  
 //Sheet layout for cutting workshop mould box sides and bases from 1800 x 1200mm panel//  //Sheet layout for cutting workshop mould box sides and bases from 1800 x 1200mm panel// 
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 ===== Downloads ===== ===== Downloads =====
  
-{{ :workshops:prototypes:slqbreezeblocksworkshop2022.pdf |}}+{{ workshops:prototypes:2022-23delivery-lasercutcovers:slqbreezeblocksworkshop2022.pdf |}}

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