w o r k i n g. .p r o c e s s
Clay & aggregate work
This work has developed out of a research project involving the adding of granular (aggregate) materials to plastic clay bodies.
The granular material I use comes from three differing sources:
Grog made by adding ceramic oxides and stains toporcelain. Pre-fired to around 900˚C, then crushed and graded to the required particle size.
Granular refractory materials obtained from refractory suppliers, such as molochite, sintered mullite, mulcoa, dense fused mullite & fused zirconium. These materials are all very stable and inert, having been previously fired to temperatures in excess of 1500˚C.
Found materials, such as granite dust and fine beach shingle. These materials are usually pre-fired and washed to eliminate any potential problems.
Once I decide on which aggregate materials will be used in a given piece, they are wedged into the base clay body.
Making of pieces involves press-moulding the clay into plaster or wooden moulds.
Following firing to around 1200˚C, all pieces are finished through processes of grinding and polishing.
Kiln cast aggregate & glass work
This unique process is an extension of the clay & aggregate work, developed through an extensive research project.
The process involves kiln-casting aggregate materials, combined with glass-forming materials.
A positive shape is first made in clay, styofoam or wood. A mould is then made of the form in either plaster or refractory concrete. The model is removed and the mould is filled with the aggregate / glass mixture. The mould containing the mix is then placed in a kiln and fired to around 1200˚C. The glass materials on heating melt and flow between the particles of aggregate material. On cooling the glass solidifies, giving a solid matrix of aggregate and glass material.
Following firing, the cast is broken out of the mould then finished through processes of cutting, grinding and polishing.
© David Binns, 2006