Technical Data
1.0 Expansion
During curing, A1 expands by 0.1% to 0.6%. The biggest advantage of this expansion is that A1 makes a perfect copy of your mould, capturing every (tiny) detail. This is why A1 looks and feels like the original.
When using a mould made of polyester, metal or another rigid material, make sure it is self-releasing.
For A1 objects that need to be dimensionally stable, use high-Shore silicone moulds or moulds made of rigid material.
2.0 Peak temperature
The peak temperature of A1 during curing is about 40 to 45°C. Even for larger volumes of A1, the temperature stays in the same range.
3.0 Not food approved
We do not have a food approval certificate for A1.
4.0 Non-transparent
A1 has a creamy white colour after curing and is non-transparent. As the A1 powder is non-transparent, we are not able to develop a transparent version of A1.
5.0 Test values for mechanical properties
To determine the mechanical performance of A1 composites, laminate panels were made by hand lay-up of glass fibre reinforcement (Triaxial Fibre 300, 160 g/m²) with A1 mixture.
6.0 Hardness
A1 has a hardness of approx. Shore D 80.
7.0 Tool cleaning with water
Skin and hands can be washed with soap and water. Tools can be cleaned with water.
8.0 Colour
Without fillers or colourants, A1 looks like cream-white stone. Slight colour differences are possible, as the colour of A1 powder varies because it is a natural product.
8.1 Freeze-thaw cycles
A1 panels were tested with 100 freeze-thaw cycles according to NEN-EN 12467. All panels withstood the freeze-thaw cycles without visible damage. In addition, mechanical tests after these cycles showed no significant difference compared to the non-exposed specimens. The differences found were within the experimental scatter. A1 (Acrylic One) panels can therefore withstand freeze-thaw cycles without failure.
The weight (density) of A1 is 1.75 kg per litre. This means you need 1.75 kg of A1 to cast a volume of 1 litre. A 15 kg set of A1 is therefore enough to cast a volume of 8.5 litres.
Adding a filler, such as quartz sand, means you need less A1, as you replace part of the A1 with the filler.
10.0 Design Guide A1 Structures
Active Composite Technologies (ACT) developed Acrylic One (A1) composites. For more than 20 years, this material has been successfully used in a wide range of products and applications. Besides the well-known benefits of composites (freedom of shape, light weight and strength), A1 offers superior fire resistance and produces no smoke in a fire. This makes A1 unique for certain applications.
ACT commissioned Dr. Ir. Albert ten Busschen, technical director of Poly Products, to write this design guide, providing a clear methodology for designing products and verifying structural behaviour such as strength and stiffness. Poly Products has more than 10 years of experience in using A1 in various products. The company also has extensive knowledge of product design, composite mechanics, production and installation.
Our Design Guide A1 Structures is a must-read for anyone designing interior and exterior A1 projects.
11.0 I am looking for a sustainable, eco-friendly material. Is A1 eco-friendly?
Every material has some impact on the environment, so no material is 100% eco-friendly. How big that impact is depends on how a material is produced, which resources it uses and what happens to it at the end of its life. Calling a material “eco-friendly” is therefore always a comparison with other materials.
A1 consists of 2 parts A1 Powder and 1 part A1 Liquid.
A1 Powder is a naturally occurring mineral that is also used in the construction industry to make drywall and other building materials. It is sourced and manufactured responsibly and has a low environmental impact.
A1 Liquid is a water-based acrylic emulsion. Acrylic emulsions are widely used in architectural, industrial and floor coatings, and as binders in adhesives and coatings for paper and textiles. Our acrylic emulsions emit no volatile organic compounds (VOCs). Although they still contain some oil-based substances, they are easier to clean up, less flammable and generally less toxic than solvent-based coatings. Their production does require energy and resources, and waste products also have an impact on the environment.
We assess A1 against five common criteria for eco-friendly materials:
- Sustainability: A1 Liquid and A1 Powder are made from non-renewable resources, but these have a relatively low environmental impact. A1 also needs little material. A1 cladding panels only need to be 7 mm thick, much thinner than concrete or brick for the same result. With an expected lifetime of more than 50 years, this means a lower impact on the environment.
- Recyclability: A1 can easily be recycled or reused. In our terrazzo, chips of cured A1 are mixed into new A1. Cured A1 can also be ground into small particles, even when it contains A1 glass fibre, as the video shows. We mixed this crushed A1 as a filler into new A1 panels and objects, adding up to 66% filler based on the weight of the A1. We are also testing other materials, such as composite wind turbine blades, as fillers for A1 objects.
- Biodegradability: A1 is not biodegradable as this makes would A1 unsuited for outdoor use. Only in cases where A1 is in contact with water for a very long period the A1 might break down into smaller substances. Although the materials used to produce the A1 are harmless, no studies have been done to determine the environmental impact of the A1 when it breaks down.
- Non-Toxicity: A1 is non-toxic and does not release harmful chemicals or pollutants into the air, water, or soil.
- Energy Efficiency: The production and use of A1 consumes minimal energy and resources which makes it very energy efficient. As A1 objects in general are lightweight compared to other materials, the cost of transportation and installation, like A1 panels, is very energy efficient.
From a marketing perspective we should classify A1 as an eco-friendly material. However, based on criteria above we prefer not to use the term eco-friendly (any more) as this might give the impression that A1 has no impact on the environment.
We prefer to mention that A1 has a low impact on the environment if we compare it to many alternative materials used in the art, theming and cladding market. The low impact on the natural resources of the products A1 is made of, in combination with recyclability, long life time, relatively little material needed, non-toxicity and energy efficiency makes A1 a environmentally responsible material to use.
This low impact is supported by the Life Cycle Analysis of A1 which concluded that A1 has an impact of € 0,22 per kg, which is low compared to many other (building) materials. The report is available on request.
12.0 Regular inspection
Even a perfectly made A1 object can be (slightly) damaged by external influences such as a collision, a storm or a very long period of moisture exposure, for example to the coating or the A1 top layer.
Therefore, inspect the A1 object for damage at least once a year. Damage can often be repaired quite easily.
13.0 Is it safe to make dishes from A1?
Technically, it is possible to make dishes and cups with A1. However, as A1 does not have a food certificate and, more importantly, is a vapour-permeable product that absorbs limited amounts of liquid, we strongly recommend not using A1 to make dishes, cups, plates, bowls or jars that will be used for food.
On the other hand, A1 is very suitable for making bowls, plates and cups for decorative purposes only.
14.0 What is the heat resistance of A1?
We have not carried out an official heat resistance test. Our own tests show that A1 can withstand temperatures of at least 120 to 140°C.
However, this also depends on the wall thickness of the A1 object and on the size and intensity of the heat source, as these can vary.
A1 users also use it to make candles and candle holders, and these work perfectly.
We also did a small test ourselves with a burner that reaches very high temperatures. Although it is not an official test, it shows that it takes a lot of heat to affect A1.
15.0 How can I remove stains from an unsealed A1 object?
Stains caused by liquids such as coffee, wine or dirty water cannot be removed from A1 that is not protected by a coating, sealer or paint system. When moisture or water comes into contact with A1, the A1 absorbs the water, including any colours in it. The water will evaporate, but the pigments or colours in the moisture will stay in the A1 and create stains. These stains cannot be removed.
16.0 A1 will undergo aesthetic changes
A1 is a mineral-based product, and its appearance will change under the influence of UV and moisture. A1 objects that are not protected and are placed outdoors will quickly lose a fraction of their top layer (a fraction of a millimetre), which often makes the colour of the object more intense. A1 objects also absorb moisture after a rain shower and become darker, then lighter again during dry periods. Accept that A1 is a natural material and that these aesthetic changes are part of it. If the A1 object must remain colourfast, a coating or paint system can be a solution.
(Left panel) A1 panel directly after demoulding.
(Right panel) A1 panel after 5 years of weather exposure.
(Left panel) A1 panel with sand directly after demoulding.
(Right panel) A1 panel with sand after 5 years of weather exposure.
17.0 A1 Powder is made of gypsum, right? Is it possible to make flower pots?
Although A1 Liquid provides better protection against moisture, A1 Powder is indeed gypsum, so you need to be careful with too much moisture. A flower pot made of A1 is at the limit of what A1 can do, because the amount of moisture can be too high, especially in a pot without a hole in the bottom.
That is why we recommend applying a coating to the inside to protect it against moisture, especially for flower pots you may want to sell. Honey Wax or a 2-component coating are possible options. Use a vapour-permeable coating on the outside, such as our A1 Sealer PLUS, so that any moisture in the A1 can evaporate again.
18.0 Train and guide your people
A1 is very enjoyable to work with and easy to process. This can create the impression that anyone can laminate an A1 panel or object without preparation or experience. Although laminating is not difficult, A1 does require attention and accuracy when it comes to, for example:
- Weighing and mixing the various components correctly.
- The short time between applying the different (glass fabric reinforced) A1 layers.
- Extra attention when applying the top layer and the second, glass fibre reinforced layer that connects to it, to prevent trapped air.
- Care when demoulding the product.
- Storing the A1 panel or object correctly after production.
That is why we advise giving yourself and your team a head start in working with A1. Let them produce a number of A1 test objects before they start on production. We especially recommend this training for people who are used to working with polyester and epoxy, as A1 requires (slightly) different working methods.
19.0 Do maintenance
With prolonged and intensive UV and moisture exposure, coating and paint systems need regular maintenance. Our tests show that A1 Sealer PLUS is also subject to erosion (especially on the sunny side), so its protection decreases over time. On the north side, and especially on A1 objects placed close to the ground, we see more algae on the test panels. Cleaning the A1 object at least once a year (with a soft brush) and applying a new coating every few years gives the A1 extra protection and extends its lifetime.
