posted 8 years ago
It is still in the molds (yogurt containers.) I can't get the 'bricks' to come out, they are stuck. It is fairly stiff, rather leathery. I can dent it with my thumb, but not deeply. If this was formwork I could have removed the forms within an hour of pouring.
However, I'm concerned that this leathery state is as hard as it will get when moist. I'm sure it will be rock hard when it dries out, but if it gets wet again and reverts to this consistency, I'm not sure if it will work for what I hope to use it for. As far as I know, there all the chemical reactions should be done by now, and hardness produced by drying would be lost when the brick is rehydrated. But maybe I'm wrong about that; as I said above, I don't really understand the chemistry of this stuff.
I'm planning some more experiments: I'd like to try acid activating the clay ahead of time; adding some non absorbent materials such as sand to reduce the amount of water needed; adding perlite to make an insulating brick; modifying the clay with magnesium oxide or potassium chloride before adding the plaster of Paris; and using wood ash as an ingredient in the mix.
Of course, at some point the amount of expense and complexity would increase till I would be better off just pouring portland based concrete. It is unfortunate that portland cement does not work as well with clay soils as with sandy ones.