I'm designing a device that calls for using papercrete insulated block or panels. But the nature of the project requires blocks that fit precise dimensions (+/- 1/4" inch or so.) A moderate amount of gaskets or seals can be used to fill small gaps. The device may have to be disassembled from time to time, so mortar is out.
An example would be a panel 5ft high, 3ft wide, 6in thick.
Does anyone have any experience making PC panels to precise measurements? If so, what's the best way to go about it?
Here's my ideas of how it might be done:
(1) Pour the mix in a horizontal mold, allow it to firm, then re-fill the spaces created by the contraction.
(2) Pour the blocks into a slightly larger horizontal mold then sand them down to size.
(3) Construct a vertical mold, then use a small scale slip form technique.
(4) Construct a form using 1 in. EPS board for the outer sides and edges, then fill the 4 in. voids with PC.
Thanks!
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