Pathways, Edges & Boundaries - Production

Once all the groups had an individual, but cohesive design plan, we began the production phase of the project.

My first task was to cut the cylindrical molds into 3 ft sections for our cylinders (1 foot would be underground) , as well as into multiple 1.5" sections to use as molds for stepping stones. The group decided on the width of the stepping stones after much discussion, and weighing of different advice and opinions.


Although we had access to a variety of power tools, none of them could be used to cut our cylindrical cardboard tubes into small sections of even with. Thus we used a hack saw and two work benches (pictured below). Cutting each section required a minimum of 3 people, one to cut and one person at either end of the tube to hold it and rotate it.



Nestling the tube in the space between the two work benches made an ideal grove for rotation. We measured the section to be cut with a ruler and then drew a pencil line for the cutter to follow. To draw this line, on person held a pencil up to the tube, while two people rotated the tube. In this way, the line was evenly drawn around the tube. It took approximately 6 hours to cut a third of the sections. Thus, this process ended up being much more time consuming then we predicted, and it was hard work!

After we had cut a number of circular sections of different sizes (including some from a small used carpet role), we duct taped them down to a cardboard base.



Other group members duct taped the edges of our cardboard boxes. still other group members cut out texturizing shapes and glued them to the bottom of some of the molds.

Once we had a variety of molds prepared, some group members began mixing our first couple batches of concrete.

It was a project requirement that each group choose their own aggregate. Our group experimented with two different aggregates. Our first choice was sawdust, because it was abundantly available in the wood shop, and thus free. In addition, its fine texture was thought to be beneficial in that it wouldn't create a visible texture.


Our second aggregate was Perlite, a growth facilitating additive for potting soil. Perlite was predicted to be a good aggregate, because it was designed to keep soil from compacting. It was hopped that it might have the same function as an aggregate in our concrete.
After mixing our concrete we scooped 1.5 inches worth into our molds and smoothed over the tops.





We let it harden over one day and one night. Then we pulled off the molds, and shook out the concrete forms.


The large cardboard box molds left a raised texture created by the indentation of the box flaps.


We didn't initially plan for this texture, but we were pleasantly surprised by it and thought that it might enhance our design. However, the pieces created from the large box molds seemed to be especially prone to cracking.

Sawdust did not work as an aggregate, the concrete forms made with sawdust had edges that crumbled (see picture above). However, the smaller forms made with Perlite seemed very solid, and had a smooth even texture.



The group did not like the look of the textured pieces, and these pieces required a lot of time, both to make and to remove from the mold. Thus, it was decided not to make textured pieces.

With only a few work days of the project remaining , our group began to make as many small forms with Perlite as possible.


We repeated the mix and scoop process 3 times. Each time we added more molds to our collection.

Plastic planter drip pans were purchased to use as circular molds, because it was deemed too time consuming to continue to cut cardboard sections. Shoe boxes made good rectangular shapes. Plastic drawer organizers from the Dollar Tree also worked especially well. Individuals were dispatched both to the Dollar store and a shoe store to pick-up more of these items.

Despite working every day of the week, by our final weekend it was clear that we would not be able to finish our pathway. So we took all of the shapes that we had made so far, loaded them into the trunk of a car and drove them to our site.


Then we worked on a new design plan using what we had.

The new plan that we decided on involved using the forms to line the edge of the pathway on one side, switching sides where the medium aligned with the building's middle. Thus, this design was very similar to our plan with the 8 and 12 inch diameter cylinders. It was noted that this new plan of using the concrete pieces to form an edge, rather than an actual pathway, worked best with the smaller pieces. Some of the wider rectangles made from wide shoe boxes ruined the perception of an edge of a pathway, as opposed to a pathway.

We decided to make as many more small forms as we could in the time remaining. The cylinders were were nixed as there simply wasn't enough time to experiment with making these much large forms. The group separated into an early afternoon and evening work group. We also bought more plastic drawer organizers and taped up some more narrow shoe boxes.