The-Artistic-Garden's Blog

Sometimes These 2 Ingredients are Hard to Get Your Hands On

I often get asked by many hypertufa and concrete garden art enthusiasts where to find “silica fume” and “poly fibers”, also referred to as “fiber mesh”. Depending where you live, it may or may not be very easy to lay your hands on this stuff.

PLEASE NOTE! Silica fume is sometimes confused with fumed silica (also known as colloidal silica and pyrogenic silica). These materials have different derivations, technical characteristics, and applications. Silica fume is very fine like beach sand and completely black.

Silica fume and poly fibers are used as strengtheners, normally referred to as fortifying agents. They help make your cured hypertufa or concrete object stronger. Often, you’ll want to use one or the other for items such as stepping stones or very thin spheres. I do have some recipes sitting on my website that I’ll refer you to, in case you aren’t familiar with recipes and/or projects that utilize silica fume or poly fibers. Here are three of them:

Hypertufa Recipe Using Fiber Mesh (Poly fibers)  (refer to last recipe on the page)
Hypertufa Sculpture Recipe
Concrete Recipe For Very Thin-walled Spheres

How to Locate Silica Fume and/or Poly Fibers

My first suggestion is to call commercial concrete supply companies in your area. Many times they will have either fortifier, and will be willing to sell you a couple of pounds. (You don’t need much of either one in a recipe – unless I guess you’re making something collosal in size! ).

I’ve even read of people walking away with some for free, after explaining to the sales people what they will be doing with the silica fume or poly fibers. Seems the sales people get a kick hearing that Portland cement is going to be mixed with peat moss and water to make an odd concoction called hypertufa!

My next suggestion is to do what else … that’s right, find suppliers who sell via their online store. In doing a Google search today, I found EpoxyUSA.com carries poly fibers for a very reasonable price on the Fillers-Thickeners webpage. Note – I have no affiliation nor experience ordering from them. Perhaps you should contact them first to check shipping charges, etc. before you order. But I’ll wager a guess they are legitimate and probably fine to deal with.

Finding silica fume online seems to be more of a daunting task. I did find this link to the SilicaFume.org webpage. If nothing else, call them and see where you can purchase a small quantity online.

So, there you have it. I hope I’ve helped you locate two ingredients that do help make a difference in strengthening concrete and hypertufa recipes.

Please Explain Deflatable Balls for Making
Hypertufa or Concrete Hollow Garden Spheres

I received an email from Debbie asking me:

In the instructions given for the Hypertufa Hollow Garden Sphere, one of the materials needed was a deflatable ball.

Can you advise me where I would get such a ball? What size does it come in and what type material is it made of? (Guess you can see I don’t have any young kids at home nor any grandchildren. )

Thanks for your help. Oh by the way, I love the project info you send. My neighbor and I have tried a lot of the projects you have sent to me in your great little Newsletter. Debbie

My reply:

Hi Debbie:
I’ll be happy to explain this for you. You can use a plastic blow-up (inflatable) beach ball like the kind you’d toss back and forth to each other while frolicking on the beach which you can buy at most drug stores, Wal-Mart, etc. Just depends upon the climate zone where you live as to whether you’ll be able to find them year-round. Stores don’t usually stock them during frigid winter months. Or of course I am sure you’ll find them on the internet. And they’re pretty cheap.

The main thing, though about using these balls for a hollow sphere mold (form) is that they can deflate S..L..O..W..L..Y and without it being noticeable in the beginning. Most normally this is due to a pin-sized hole that allows the air to escape. I know in my case, as a kid, sometimes I’d find that my new beach ball was pretty much totally deflated within about a day. This was probably caused by a tiny pinhole leak.

Now … add the weight of a heavy, wet ‘tufa or concrete recipe pressing down on the ball. The weight helps to accelerate the air escaping. Some crafters have reported that when they came back the next day to inspect their sphere to see how it was curing – yikes! They found a pretty sad looking deflated and slumped down sphere.

Now … perhaps this “disaster” might prove to be an interesting sculptural form that once cured can be painted and utilized in some other fashion, but let’s just say most folks end up having to trash the project. So … “cheap” beach balls are quite OK most of the time and hold air without causing a project failure … but just be aware of the potential deflation problem.

Or you can get one of the big heavy-rubber inflatable types that people use to exercise with. These can be found at Wal-Mart or Target in the exercise depts. (as examples) and just the other day I saw some at T.J. Maxx for sale. This size ball would of course be used if you want to make a really big garden sphere. But deflation problems from small leaks most likely won’t be an issue for you.

Now, there are other smaller, sturdier type balls you could use, but you asked about inflatable/deflatable, so I am mentioning the most often used balls. You want something with a stem you can blow into or can hook-up an air supply to for automatic inflation. And the stem allows you to deflate the ball easily after your sphere has cured enough.

Good luck with your hollow sphere project!

A Reader Asks Construction Questions About A
Decorative Cast Leaf Fountain

I received an email from Jan R. asking me:

Hi there, I want to make a hypertufa leaf or concrete leaf fountain. After the leaves are made how would I form the fountain and to what? Got any ideas? Thank you for your time.

Sincerely, Jan

My reply:

Hi Jan:
Thank you for contacting me about making a concrete or hypertufa leaf fountain, which is a fun project to do. The answer to your questions will be rather difficult ones to answer at this point, as you’ve not told me how the leaves are to catch and/or collect the water; how many levels you want; or what sort of base you want the fountain to set on, to name a few.

Make sure you read through the ins and outs of working with hypertufa and concrete for leaves. Here are a couple of articles on my website that will be of help: Leaf Casting with Hypertufa: Tips for Success, and Concrete Leaf Casting: Super Tips From the Pro’s.

There are many variables I’d have to know in order to walk you through this, but basically here is what I believe will help you think this project through:

• Most crafters make two or three leaves set in a tiered fashion, and at angles to each other, which allows the water to spill over the edge(s) and finally collect in the bottom leaf.
• Joining all the pieces can be accomplished by mixing up a fresh batch of your recipe with bonding agent included in it and some bonding agent also painted onto the areas of where everything will be joined for good measure. (You would have to wait until the leaves were cured enough to be handled before you start joining them.)
• You need to seal the concrete or hypertufa leaves with a water-proofing sealant.
• You need to know how to install a simple pump in order to get the water flowing back up to the top-most leaf; you also need to get a pump that has the right GPH rating to effectively keep the water flowing.
• Another consideration – WHERE are you going to hide the pump and cords? Inside the base, or …? I wouldn’t think you want the pump and connections visible.
• You will need a GFI electrical connection available to plug in the motor for the pump. **There’s no side-stepping this requirement – water + electricity do NOT mix!

To learn about GPH and GFI, read this article on my website. Skim about half-way down: Garden Spitters Installation: GPH & GFI Considerations.

This is as specific as I can be for you at this time as I’ve no clue as to what actual shape/form you want your fountain to have. Nor how large you foresee the thing to be. What kind of leaves do you plan on using? Huge gunneras or something medium sized?

But, I do hope these tips help get you to thinking and sketching your ideas out on paper. Though not the easiest project, it is quite doable. Obviously your creative skills will really come into play with a project like this!

Good luck. I really hope you are successful with this leaf fountain project … personally I think there’s nothing nicer than the sound of trickling water in my garden.

Hypertufa Rocks Project
Making Hypertufa Boulders for a Waterfall

I received an email from Carole M. asking me:

Could hypertufa be used to create boulders to be used on a waterfall on a pool? We built one that needs help. Thanks!

My reply:

Hi Carole:
Thank you for contacting me and if you are referring to using a hypertufa recipe (or even a concrete recipe) to make boulders for your waterfall … yes you certainly can use the appropriate recipe for this project.

I suggest you read over ALL the pages of hypertufa and concrete information I have on both my website and my blog pertaining to hypertufa and/or concrete projects. There are things you need to be very aware of if your finished project will be in contact with plants or pond fish.

**Let me caution you that whether it’s a ‘tufa or concrete rock you are making, the thing you really must do as a final step before you allow plants or fish to come into contact with water that is in constant contact with your rocks or boulders, is to leach the lime residue out of the rocks/boulders (or even a trough or planter for that matter) completely.

This important step cannot be over-emphasized as necessary to do! Read more about that here: Build a Hypertufa Garden Pond Waterfall.

In addition, I will make a shameless plug on my own behalf, and recommend you purchase my Hypertufa eBook, as there is more in-depth information there that will be helpful to you. You can find information about my eBook here: HypertufaBooks.com. The eBook will more than pay for itself after you’ve made your first boulder, for sure!

A hypertufa or concrete boulder project will be quite an undertainking for you, so I will advise strongly that you do a small “test” project, or couple of projects, using the recipe you decide upon. Get the hang of working with the recipe; the curing time, etc.

Here is a blog post you will find informative since you’re new to working with recipe mixtures containing Portland cement: The Number #1 Cause For Most Hypertufa and Concrete Recipe Failures.

Best of luck in tackling your hypertufa boulder project!