The material

What is resin based polyconcrete?

 Resin based polyconcrete is a mixture of polymer resin and a number of fillers, that range from coarse sand to fine powders, reinforced with glass fibre strands.  This mix varies according to the weight and complexity of the moulding and can be pigmented to any colour.

Once moulded, the product is then covered with a polyester top coat that is a pigment match to the core material.

 

What is glass fibre reinforced polyconcrete?

Glass fibre reinforced polyconcrete is a glass fibre matt wet out with resin to various thicknesses depending on strength requirements.  Again, once moulded, the product is then covered with a polyester top coat.

 

How is an item manufactured out of resin based polyconcrete?

The required mix is poured into a prepared fibre glass mould, after an aeration process that removes as much air as possible from the mix to reduce bubbles and pinholes in the final product.  After the initial curing time within the mould, the product is removed from the mould and allowed to cool.  Once the final form has been reached, each item is sanded down and then placed in our oven for post curing.  The final polyester top coat is then applied.

 

How is an item manufactured out of glass fibre reinforced polyconcrete?

In this case a 0.8mm gel coating is applied to the inside of a prepared mould.  Once this coating has cured, a series of glass fibre reinforcing layers are applied to provide the internal structure of the item and left to cure.  The item is then removed from the mould and then post cured in our ovens and left to cool.   The final polyester top coat is then applied.

 

Is there steel reinforcing inside to support the structure?

No.  Strands of glass fibre reinforcing are used to strengthen each item.

 

Why do you state that it is light weight, when it is still really heavy?

Each item in the resin based polyconcrete range is approximately half the weight of a comparable piece made from traditional cementitious concrete.  Items made from glass fibre reinforced polyconcrete are between two-thirds and three-quarters lighter than traditional cementitious concrete.  This has significant implications for applications where there are load bearing structures and where cranes need to be brought in to lift and position items.

 

Does it scratch?

The top coat provides an impenetrable outer layer to the product which limits scratching from ordinary use – for example rings and keys scratching the surface, toys, shoes, metal elements to bags etc.

 

Can it be damaged?

The material can certainly chip or scratch if it is systematically vandalised (for example, if someone with a hard metal object takes their time to dig into the top coat surface) or if it is slammed into another piece or a wall.

 

What happens if it is scratched or chipped?

We can repair these items, but it does require the item being returned to our factory and a service fee for the work required.  Alternatively, Igneous and the client can enter into a maintenance agreement with regular intervals for repairing and respraying any items on site.

Please note that the colour of the polyconcrete is embedded throughout the entire product and the top coat is an exact match to the internal concrete colour.  We have therefore minimized variations in colour throughout the product and therefore made scratches and chipping less visible.

 

Does it stain?

No, the sealant is stain resistant – including staining from red wine, blood, rusty items, intensely coloured fruits and berries.

 

What other properties make the material superior to other options?

Our resin based polyconcrete is fully weather resistant, water repellent and requires very low maintenance.  The polyester top coat finish is also acid and alkali resistant, including resistance to chlorinated environments.

 

Are the colours really colour fast and UV stable.

Yes, we guarantee that our colours will not fade, chalk or yellow.

 

Are these the only colours in your range?

No, the twelve colours in our colour range are our standard colours, however there is an endless number of colour options available.  Each new mix of colour does carry a small surcharge, which covers the pigmentation of up to four rockers, loungers, ulterior tables or an approximate 500kg of resin based polyconcrete.

 

How do I clean it, maintain it?

We recommend that our furniture and pots are cleaned with soapy water, using standard household detergents or an industrial equivalent.

 

Can you put holes in to assist with water drainage?

Yes, we can drill into the material after it has cured.

 

Can you make a custom designed item?

Igneous Concrete is a customer-driven company, encouraging clients to custom design furniture or related products to suit their landscaping, architecture or branding.

We do however need to offset the cost of a new mould, and custom items are generally considered with a minimum quantity of 10 items.  The mould then becomes the property of Igneous Concrete, with exclusive rights to reproduce the item for clients other than the commissioning client.  Where clients wish to retain ownership of the design, they need to pay in full for the costs of the mould.

More information about Custom Design