Flint Panel Edging

[Onoff]

I was hoping to use this Ferrex paddle mixer I bought from Aldi a while back to mix my mortar up. Used it only once since I bought it but it's been hanging in the garage ever since.

Plugged it in and it just hums!

The paddle / shaft turn freely enough by hand.

Out with the screwdrivers!

 

[Onoff]

A few shots of new flint work to see here there are others but a couple of interest at 30:40

https://www.my5.tv/alex-polizzi-my-...pisode-3-06803167-afd6-4514-b55a-3f2ba6d4e223

Notice the difference between the new low wall and the patch behind Alex, presumably both done with the same mix, but drying out differently.

I'm often in Alfriston, but it's been screened off, so must go and have a look sometime.

Brilliant! SWMBO just mentioned she watched it last night. I'll sit down and take a look. Nothing to do with Alex in her leather boots...

I've taken a bit of a slagging on another forum with someone suggesting the hydrated lime I have might not be the right thing for this and I should have used hydraulic.

On the sample front the 2:1 mix seems to just getting harder with it getting harder to dig your nail into the face. The 1.5/0.5/1 is still soft on the face. You can still, in both cases, crumble bits off quite easily where it's still damp.

 

[Gritineye]

LOL believe me I was slagging myself off for using it, but the customer is always right. Maybe I need to get up there and have a close look, it's been a few years now.

 

[Onoff]

@Gritineye, I'm really not sure if this stuff is any good. It's not according to the bag!

"...it is not suitable for use in mortars and renders without a cement".

 

[Onoff]

Just playing with laying out the flints I have. Basically got 4 boards and marked the area to fill. Vague recollection of someone saying aim for a finger width's of mortar between the flints.

I do have a set of copper boppers I bought but struggle to shape the flints tbh.

I think, in all honesty I'd prefer the mortar for the flints to match the 4:1 I used for the bricks. Is there any way to make it (the mortar) "flexible"?

Adding lime I believe acts as a plasticiser, is that the same thing?

 

[Onoff]

I'm coming round to the idea of not using lime and just opc, I can keep the new bag of lime for getting for getting rid of the body...

The one thing I will say about these no opc, sand/lime mixes is they seem to be getting harder by the day. Is it something to do with them absorbing atmospheric CO2 and eventually reverting to limestone?

Video of the 2 sharp / 1 lime sample:

https://flic.kr/p/2mjXxZ5

Then the 1.5 sharp / 0.5 soft / 1 lime:

https://flic.kr/p/2mjTLby

As I understand the method of laying flints I need to place a board against the wall then hold the flints tight against the board and infill from behind. Quite how that'll turn out when I remove the board I don't know as I'm guessing an opc mortar might dry quicker. Maybe there's an optimum for removing the board with slump and still being able to tidy round the flints.

Yet again, soft sand or sharp if I go with opc and no lime?

Aiming to start tomorrow whatever and hope!

 

[Onoff]

I quite like the complexity of this mix suggested on another forum:

"When doing flint work I use 4 sharp sand, 2 soft washed(building sand), 1 lime and 1 white cement".

 

[Onoff]

Here's a mad thought...

Time and techniques have moved ever onward. The issue with using normal cement mortar is one of shrinkage around the flints, frost action and cracking. Could I perhaps lay them in the same 4:1 mortar mix I used for the pillars then when cured just spray them with a water seal like Thompsons or Permagard?

 

[Onoff]

Still undecided as I am on mix I knocked up a quick frame of pallet wood, divided into 4 to represent the 4 flint panels. Dumped some sharp sand in each. Apparently I get to choose the stones for one then SWMBO and the kids one each.

This is my attempt (the rectangular gap at the end nearest the camera is where the intercom sits). I might change the couple of whiter stones for blacker ones.

To give an idea of scale:

I've read that "fist size" are ideal but without knapping them this is the best I can do. If I start knapping I'll likely end up with just loads of broken flints!

 

[Onoff]

All this experimentation isn't getting my pillars finished! Another trial mix slopped out on a board, top left of the pic.

- 3 soft
- 1 sharp (figured it'd add strength and maybe some interest with the fines in it)
- 1 opc
- 1 lime (for plasticity/self healing)

Made it too wet as usual!

I've two kilos of buff dye here. I'm thinking to divide into 8, then do the panels in 8 hits. That is do half an 820mm high panel at a time, that'll be nom 18" height wise, so add 250g of dye powder to each mix to "yellow" up the lime.

 

[Onoff]

Time for a rest from thinking about flints and to re make the top rollers for my gate. The "temporary" ones haven't done bad.

The top of the gate is an upturned PFC. One gate post "hooks" over this. A bit of a nod to an anti lift detail too.

I literally lashed something together umpteen years back with some buffalo board, bolts and reinforced hose. The hose was warmed up and encouraged over some stock nylon I have here.

You can just see the rollers here:

The temporary rollers removed just now:

For whatever reason the reinforced hose "tyre" on one roller has flattened one side, over time. I can only imagine the roller stopped turning at one point. The flat is top of the top right roller:



Off then to the store of collected tat for a redneck fix!

 

[Onoff]

That'll be why, seized with rust. I wonder if the nylon roller absorbed water?

Forgot I had these done. 4 20mm stainless plates. I paid for them to be plasma cut and they made a pig's ear of the edges, square edges my ar$e! Seem to recall that's why I didn't use them then.

I drilled previously 4 holes in each at 5/8" as I didn't/don't have a 16mm bit! They measure nom 85x85 and the 100mm box is 5mm wall.

So a nom 2.5mm gap all round. I think I was planning a rubber packer or tap type washers as an aid to isolating the rollers from the post and helping to reduce rolling noise...

A rough plan is forming / re-emerging...either find, some more 16mm st/st bar I'm pointing to. I did have 4 kicking around, they're tapped M8 both ends. Or use M16 stainless studding for new shafts and turn the ends down to suit the hole through the nylon. I can likely reuse the original nylon rollers with a new "tyre" on one:

 

[Onoff]

I'm liking my last mix, the way it's drying, easy to dress around the flints with a soft brush too. A few speckled fines showing in the mortar:

 

[Mick Annick]

I'm liking my last mix, the way it's drying, easy to dress around the flints with a soft brush too. A few speckled fines showing in the mortar:

View attachment 308266

Are you overthinking the flint placement? I remember from doing a bit of drystone walling to only handle each stone once.

I appreciate you want it to look good, and I know nothing about lime mortar! You could always have a look at SPAB - Society for the Protection of Ancient Buildings.

 

[Onoff]

You could always have a look at SPAB - Society for the Protection of Ancient Buildings.

Me, overthinking? Guilty!

I think I got sidetracked with the whole historic look and the "white" mortar norm. All I want is the flints visible in the modern brick pillars. Not trying to make it look like a church or match anything else. I'll likely go with this mix if I like how it's dried out a bit in the morning.

I was thinking to use wire mesh to keep the infill in place whilst it's going off, old oven racks to be precise, ratchet strapped round the pillar. Bet they didn't think of that in the old days!

Maybe some masonary waterproofing cream afterwards...

 

[Onoff]

Quick fix with a new roller printed in grey PLA. Bolt derusted after a citric bath and re assembled with a good smear of sapphire blue.

Whilst I work on the new, all stainless one.

Gate rolling again without jamming!

 

[Onoff]

Some rollers in PLA for the new assembly. Quite how long they'll last! These will run at very low speed on stainless steel plain shafts.

 

[Onoff]

I've decided on my mix. Was waiting for SWMBO and the kids to lay out their panels. SWMBO had a go and imo it looks alright but I don't think it'll work as there's little depth to the stones she's chosen. Thinking they'll fall out over time?

 

[Onoff]

Out for a walk earlier, there's a local mansion with flint walls.

Interesting here how it's like they've drawn a finger around each flint. Don't know if that's a particular technique?

 

[Blobber]

Out for a walk earlier, there's a local mansion with flint walls.

View attachment 310377

Interesting here how it's like they've drawn a finger around each flint. Don't know if that's a particular technique?

View attachment 310376

Personally I think that looks horrible, you can see the moss and stuff taking hold in the ridges, your running out of time winters coming! get them stuck in job done!