Concrete Fence Business: How to Start? Form for the production of concrete fences Equipment for the production of concrete fences

Concrete fences are designed for fencing residential buildings, enterprises, social and cultural facilities. Form, height, presence or absence design solution is determined by the type of development, location, operation, technical and economic indicators, etc. Fences on private grounds are the first stage of arrangement for your comfort and a source of pride for the owner.

For the manufacture of fences, the casting method is used, it is most effective in the production of products of small thickness (including roofing tiles, paving and facing tiles, fixed formwork, MAFs, etc.).

For the manufacture of concrete fences are used:

portland cement М500Д0 (without additives);
sand with a fineness modulus greater than Mkr 2.0 ( perfect option - fraction 2.5), the content of clay particles in the sand is not more than 3%;
granite crushed stone of more than 800 grades, fraction 5-10 mm is allowed;
plasticizing additives;
water;
reinforcement: for the frame - steel Вр-1, diameter from 4mm, for posts: 0.5m - В-1 4mm, 1m - Вr-1 4mm, 1.5m - 6mm, 2.0m - 8mm, 2.5m - A3 10mm.

For the production of concrete panels for the fence, this mortar recipe is also used.

The concrete mixture should be prepared in a special mixer, then it will have high mobility, non-segregation, excellent casting qualities, as a result, the products themselves will be strong, frost-resistant and have a long service life.

Concrete fence manufacturing technology

The loading of the ingredients of the solution must be carried out in the sequence: sand - cement - water.

Pillars. Rinse the gravel in a concrete mixer, drain the water. Add sand, after cement. Knead everything dry until smooth. Pour water in portions, the moisture level is checked visually (squeeze the mixture in the palm of your hand).

Attention! The mixture on the pillars, is made more dry than on the slabs, should visually be lumpy. If, during vibration, the solution in the molds begins to "boil", it means there is excess moisture, which will lead to the "sagging" of the products, which is not desirable for the pillars (the inner part sags when it sets).

Add half of the estimated amount of crushed stone, plasticizer solution and about half of the total amount of water to the mixer, mix for a minute. Then fill in the estimated amount of cement (see table) and repeat the action for another 1 minute. Then add the rest of all components (gravel, sand). The total time of the whole process is 10-20 minutes, depending on the volume.

Plates. The solution can be made in a forced mixer, provided that it is unloaded from a height of no more than half a meter.

How to determine the quality of concrete?

The mixture should not contain dry inclusions, delamination during vibration. It is easy to roll a ball from it (it has the consistency of soft dough).

Quality parameters:

Density - 2200 kg / cubic meter. (GOST 26633-91 "Heavy and fine-grained concrete").
Compressive strength class - not less than M200 (GOST 18105-86 "Strength control rules").
Frost resistance - not less than F50 (GOST 100060.1-95 "Concrete - the basic method for determining strength").

Technology for the production of concrete fences and pillars

On condition of spatial separation of the mixer and vibrating tables, the mixture is unloaded into hand carts. Otherwise, the best way - a sheet of tin under the mixer.

Fences. Start the manufacturing process as follows: set the molds on a vibrating table, apply the release agent manually, with a special tool using a brush or spray (the second method is more economical). If an excess amount of grease is formed, drain it.

Fill the matrices with a semi-dry concrete mixture to a third of the container. Run the vibrating table for about 30 seconds to compact. Install the reinforcement, re-start vibrations. After full immersion of the reinforcing wires, wipe the surface until smooth.

Pillars. Place the mold on the vibrating table, insert the side inserts and secure with screws. Lubricate. Pour a third with concrete, turn on the table for 30 seconds, install 2 reinforcing rods, add the second third of the mixture and 2 more rods, pour out the remaining solution. Run a vibration table between all actions. After complete filling, the inner insert is laid. The end is deepened with a board across the form. The vibrating table is included. Smooth the surface around the groove with a trowel, holding the board to the level of the form. Turn off vibrations, finally smooth out the shape.

When making pillars, during the final filling of the form, it is necessary to install the upper groove.

The stripping process takes place by tipping the mold onto wooden pallets. Then slowly raise first one, then the other side until the product is completely separated, remove the matrix, check visually the quality.

After all the work, the matrices are cleaned of adhering pieces with brushes, in extreme cases with Barracuda or a weak solution of hydrochloric acid.

Hardening occurs due to the heat of hydration of the cement. All products are placed on pallets, the latter are stacked no more than 10 pieces on top of each other. If the room temperature is below 5 ° C, cover with foil. Do not give piece to heat treatment!

Transportation can be carried out with a set of at least 70% strength. Store panels vertically, posts horizontally.

Paint with facade paint.

Concrete mixes
(consumption rates of raw materials and materials, per 1 m 3 of concrete mixture)

Optimal concrete compositions are proposed for specific operating conditions, ensuring maximum product durability. Recommended concrete mixes are presented in the table.

Name of raw materials	Heavy concrete (sidewalk coverings)		Fine-grained concrete (sidewalk coverings)		Lightweight concrete (facade coatings)
	Consumption rates for 1 cbm.	Consumption rates for batch V-0.5 cbm. Container-bucket V12L	Consumption rates for 1 cbm.	Consumption rates for batch V-0.5 cbm. Container-bucket V12L	Consumption rates for 1 cbm.	Consumption rates for batch V-0.5 cbm. Container-bucket V12L
Cement, kg	485	16	580	20	500	16
Sand, kg	930-890	24	1480-1435	40	640-600	16
Crushed stone (expanded clay), kg	850	24	-	-	450	32
Plasticizing additive	consumption depending on the used additive
Water, l	160	5,5	195	6,5	170	5,5

If you have any questions, please contact our manager-consultants. We will advise, help, advise!

Choosing a fence for your suburban area, at home or in a cottage, many are trying to keep up with the times. IN last years concrete fences are very popular. And these are no longer bulky gray slabs with straight lines and outlines, thanks to technology, sections of various colors, shapes and sizes can be produced.

It is worth noting the advantages of such a fence:

reliably protects the territory from the invasion of strangers;
has a reasonable price;
attractive appearance;
long service life;
does not require additional maintenance.

To make sections for a concrete fence, special shapes are required. Moreover, they are divided into several types, thanks to them, the products differ favorably from each other:

For the manufacture of spans that have clear straight lines and regular geometric outlines, use polyurethane and durable plastic molds.
To create a textured base, reliefs and bulges allow shapes made of fiberglass or polyvinyl chloride (PVC).

It should be noted that the strength of the fence will depend on the quality of the form in which it was made and the mixture of the desired consistency.

Types of forms, their advantages and differences

Polyurethane

Not so long ago, double-sided polyurethane molds appeared on the construction market. They have great strength, due to their rigidity, they have a long service life (withstand up to 100 cycles of laying concrete mixtures). Thanks to them, the fence has a beautiful appearance from both sides.

Such forms provide almost any pattern and relief. Often the sections made in them are of the form decorative stonethat goes well with metal, plastic and other materials.

At the same time, there are disadvantages to which one cannot turn a blind eye:

the high cost of the material itself;
chips often occur, due to which the pattern of the fence is obtained with noticeable defects;
the product is difficult to get out of such forms, therefore there is a large percentage of defects.

It is quite easy to create fence sections in such shapes. To do this, a special solution of fiber-reinforced concrete is poured into them and vertically installed on a vibrating table. Later 12 hours the product solidifies completely.

PVC

Perhaps the most widely used forms. This is due to their low cost. In addition, there are a number of advantages:

a large assortment;
there is practically no marriage;
high quality of the finished product;
durable (allow 100 fillings);
fire resistance.

The finished span must dry not less than a day (it is advisable to use a drying chamber). In order not to interrupt the manufacturing process, a sufficiently large number of forms will be required. Required condition - the mold should have handles so that it is convenient to carry it from the vibration table to the drying shelf.

Thanks to them, you can get plates various shapes, structure and color. There is a possibility of decoration for granite or marble.

Fiberglass

They are suitable for those who are ready to start painting a section after its production and installation. It is technically impossible to change its color in the process of creating a slab, since adding a dye to the mixture violates the strength of the product. When it is removed from the mold, there are chips and various defects.

Such forms have a thickness of at least 8 mm, along the entire perimeter they are framed with a metal frame to which the handles are welded. They are designed for easy portability. Plates can be produced using the quick ejection method or by drying within 24 hours. The second method is usually not used. It is considered unprofitable.

ABS plastic

In factories that manufacture concrete fences, mostly use just such forms. They have a number of advantages that distinguish them from other options:

high strength of finished products;
long period of operation ( 200 pouring processes);
durable, as they are made of chemically resistant plastic;
the flexibility of the form makes it easy to remove the product;
assembled have compact dimensions;
do not require additional processing before pouring the concrete mixture.

What to choose?

Forms for the manufacture of concrete panels from ABS plastic and PVC are advantageous in price, but the extraction of the finished product is possible only after the mixture has completely solidified and dried. Therefore, they will be convenient only if you have the right number of such forms. When working with ABS plastic, a vibration table and a special drying room are not required, it does not need to be coated with grease.
Forms made of fiberglass are very durable, absolutely not afraid of ultraviolet rays. The product, which has not yet hardened, is placed on the surface of an iron tray and left to harden.
Polyurethane molds have recently appeared on the domestic market, therefore they are not very popular. The repulsive factor is the high price.

Many people wonder whether it is possible to make such forms with their own hands. The obvious answer is no. To create such products, you need:

special material;
special equipment;
huge store of knowledge;
chemical reagents that are unsafe to work with.

How to install concrete fence posts - see this article.

How to make concrete blocks for a fence with your own hands, read here.

Manufacturing technology of concrete sections

There are several technologies that specialists use to make decorative concrete spans for fences. The most popular is rapid ejection method... It allows you to produce about 20 sections per day.

The essence of the method is as follows:

The mold must be installed on a vibrating table, soaked in grease, loaded with ready-mixed concrete, and turned on vibration.
When the solution fills the mold by more than half, the product is reinforced with a flat steel wire frame.
Add the solution to the base, without turning off the vibrating table. The slab is leveled with a spatula, the excess is removed.
When the back side acquires a smooth surface, remove the product. With the help of special handles, the form is transferred to an iron tray for drying, placed vertically on one side, and the product is turned over with cotton. Moreover, it can already be used to make the next plate.

The work process can be clearly seen in the following video:

In order for the process to be continuous, you need to take care of the racks on which the finished products will dry out. It is better to do this in a special room in which a certain temperature regime, the moisture level meets the standards, there are no drafts.

Supporting concrete pillars are made in a similar way. The process is the same in time, but the material is consumed in half. You need to understand that drying shelves will also be needed for the supports.

Another nuance that should be taken into account - the finished products will have only natural color (gray), dyes will not work in this case. Experts have proven that the addition of colored pigments negatively affects the process of concreting and hardening of the finished product. Ultimately, you may end up with a slab with chips and other defects. This can affect the strength of the entire fence, and also entail additional financial costs.

But the situation can be corrected. To do this, it is enough to paint after the installation of the entire structure.

To get the colored sections initially, you can use another method. It is not very common, since it takes a lot of time to make and solidify the plates. The technology is as follows:

The required forms are filled with concrete mortar, leveled, and the excess is removed with a spatula.
Leave for 24 hours until complete solidification, while the form cannot be moved.
The finished product is carefully removed from the mold.

With the advent of the rapid ejection method, this technology is used less and less. It is considered unprofitable and is only suitable for creating sections at home, when you have a lot of time and the installation of the fence can wait.

It is better to entrust the creation of sections to professionals and purchase ready-made products. In this case, you will be sure of the quality, reliability and durability of the structure.

Modern fences are not just a means of protecting a summer house from intrusion, but also an opportunity to declare your status and good taste. The easiest way to make a reliable decorative fence with your own hands is from type-setting concrete sections.

Decorative concrete fence with stacked posts

What are the fence sections

Decorative fences are made from the same material as conventional concrete fences. The main difference between decorative sections is the production method. With the help of specialized casting molds, concrete panels are given a different texture or openwork outlines.

This is what concrete sections look like for a type-setting concrete fence.

Sections decorative fencing stacked of horizontal narrow panels (about 50 cm) stacked on top of each other. Thanks to the individual sections, you can create an exclusive fence by assembling the fence panels in different ways. It can be a solid canvas like a stone, brick, wood or a fence with openwork carved inserts.

Dividing the fence fabric into separate sections facilitates the process of transportation and loading and unloading operations. The installation of the fence is also greatly simplified and accelerated. Another advantage of decorative sectional fences is the ability to adjust the height from low flower beds inside the cottage to impregnable four-meter fences.

Advantages and disadvantages of a decorative fence

Among positive qualities sectional fencing is worth noting:

It is difficult to find flaws in such a fence, but it is still possible:

Concrete fences are expensive compared to fences made of metal mesh or wood.
Another disadvantage is the likelihood of purchasing low-quality products from unscrupulous manufacturers.

A concrete fence will be truly reliable and durable if high quality raw materials are used for its production and a responsible approach to the production process.

Shape and pattern for sections of concrete fence

To be sure that the technology was followed at all stages of production, fence panels for summer cottages can be made independently.

Forms for decorative fences

Decorative fence panels are produced by vibration casting from high-quality Portland cement, refined sand, gravel, and reinforcement. Often in cement mix dyes are added to give the finished products different colors.

Direct casting is carried out in specialized molds-matrices, which give the sections various textures and patterns. Forms for sections can be purchased in hardware stores, ordered online or made according to an individual sketch.

Types of forms for decorative sections

Dies for concrete panels can be made of various materials:

Polyvinyl chloride (PVC)

One of the most popular and affordable options is PVC matrices.

They are flexible, provide high quality finished concrete panels and are fireproof. Such forms are often used in rooms with high fire safety requirements.

Polyvinyl chloride forms are presented in a wide range and have a good service life (they can withstand about 100-150 production cycles).

The price for PVC molds is low and depends on the complexity of the texture and pattern. Such products are well suited to work on a production scale.

ABS plastic

ABS molds are very durable and made of tough, chemically resistant plastic. Most often they are used to obtain concrete panels with a clear pattern; high rigidity of the forms ensures the geometric correctness of the finished product.

ABS matrices have the following advantages:

Polyurethane

Polyurethane molds make it possible to reproduce the most complex textures on concrete: natural stone, slate, wood. Due to the increased elasticity of the material, all the details of the pattern are very clearly traced. Most often, polyurethane is used to create decorative double-sided fences, and can withstand up to a thousand production cycles.

The disadvantages of the material include the following points:

Fiberglass

Fiberglass molds are very productive - even with one die, you can produce up to 50 items per shift using the fast stripping technology. Therefore, it is not necessary to purchase a large number of molds for the production of sections. Quick stripping is facilitated by a full metal frame and comfortable handles.

The downside of fast ejection is the impossibility of making painted panels. Pigments reduce the strength of the concrete and can cause defects and damage during stripping. Painting is done only after the installation of reinforced concrete fencing.

Production of decorative fences

The process of making decorative sections is simple, the main difficulty lies in the preparation necessary materials and tools.

Necessary equipment

forms for concrete sections;
concrete mixer;
vibrating table for forming concrete products;
vibrating sieve for cement and sand;
drying trays for finished sections.

For the production of concrete sections on a production scale, the most expensive item is the acquisition of molds. It takes a lot of them to provide a variety and a normal volume of products per shift. For the manufacture of decorative sections for your own needs, you can buy one or two forms, and they are not very expensive.

Another important tool for creating decorative sections is the vibrating table. With the help of vibrations, the concrete in the molds is compacted and gets rid of air bubbles and voids that reduce the strength of the concrete structure. The vibrating table can be bought, rented or made by yourself. On the Internet, you can find ready-made drawings of a homemade vibrating table.

It looks like a vibrating table for casting concrete products

In the manufacture of concrete products, the use of a concrete mixer is preferable to manual mixing, in which the components are mixed more thoroughly. Mechanical vibrating sieve is designed for cleaning sand and cement from debris. For small volumes, bulk materials can be sieved by hand.

Raw materials and supplies

For the manufacture of decorative sections, you will need the following materials:

portland cement grade 500;
wire reinforcement;
quartz sand GOST 8736-93;
crushed stone;
various plasticizers to speed up the setting process.

Stages of making a decorative fence

Instant demoulding

High-strength fiberglass matrices with metal frame... Special handles are convenient for quick product ejection. For this technology, the use of plasticizers is highly desirable, and the mold should be lubricated before pouring. All these actions will reduce the amount of scrap when removing a section.
Sequence of operations for instant stripping:

a lubricated form is installed on the vibrating table;
concrete mix is \u200b\u200bpoured;
fittings are laid;
the product is compacted on a vibrating table;
the concrete section is laid out on the stripping table;
drying section.

Features of exposition casting

The main difference between the technology of exposure stripping is that the strength of concrete occurs in the form.

Mold for exposition casting

For casting, matrices are used from quality materials with high-precision patterns: PVC, ABS, polyurethane. From the moment of compaction on the vibrating table to the stripping of the section, at least a day must pass. If the technological requirements are observed, the surface of concrete panels made by the method of exposure casting is smooth, with a clear pattern and does not need additional processing.

Drying of concrete products should take place at a temperature not lower than +15 degrees. After about 5 days, the panels can be considered ready for transportation and installation. Although the full maturity of concrete products will come only after 28 days.

Drying concrete fence sections

Making a decorative and reliable fence for a summer residence will not be difficult even for a person without special skills. Armed with the knowledge, the necessary equipment and the desire to create, you can create a fence that will delight you with high strength and aesthetics combined with a low cost.

Many people who want to put a concrete decorative fence around their site have an idea to make it themselves. This desire is usually dictated not by cost savings (most often the cost of the finished product and the one made by yourself is not much different), but by the desire to be confident in the quality of the concrete mixture and reinforcement. The use of only high-quality materials and careful attention to the manufacturing process is the guarantor of the durability of the fence. Some go to this laborious process for the sake of making a unique unusual product.

Solid original concrete fence.

What does a concrete decorative fence consist of?

A concrete fence structurally consists of several elements that you can make yourself. It:

section plates,
pillars,
caps on the pillars.

Slabs for sections differ in shape, patterns, texture, color. One-sided and double-sided plates can be made.
The pillars can be made solid and inlaid, with grooves located opposite each other and at an angle of 90 degrees for corner posts or without a groove at all, as well as with a different pattern.
Caps can be ordinary pitched, round, dome type, square, with small architectural forms - with balls, spears, rhombuses, etc. at the top. In the hoods, you can immediately provide for the presence of a hole at the level of the casting for a cable outlet for lighting or communications.

The ball cap gives the fence a finished look.

Molds for casting

For the manufacture of any elements of a concrete fence, casting molds are required. A wide variety of shapes can be seen on sale. Forms from

polyurethane,
polyurethane with plasticizers,
silicone,
fiberglass,
formoplasty,
aluminum, etc.

Traditional polyurethane molds are durable, easy to use, tear resistant, elastic. Buying ready-made forms is the best option for those who are satisfied with a typical fence, but who want to independently control the quality of materials for manufacturing and the technological process.

Fiberglass molds for casting.

For those who dream of an exclusive fence, there is nothing left to do but to make forms on their own.

How to make a die for a mold

To make a mold from polyurethane or silicone, you need a matrix. The matrix on one side represents the print in the mirror image of the outside of the mold. It is inserted into a box made of metal or wood, into which it will be poured concrete mortar... The sides of the die must have a flat, smooth surface.

Formoplast for making molds.

In order to make the shape of the matrix, you need to find a product, the shape and relief of which will be repeated on the surface of the fence: it can be a brick, a wide variety of stones, wood, as well as patterns made, for example, from a rod or forging. These embossed products are laid on the surface of the base and filled with a liquid forming material.

The matrix is \u200b\u200btreated with a release agent.

The material for making the forms must be strong, smooth, wear-resistant, able to withstand high temperatures... These materials are traditional PVC and modern ABS plastic. For a long time, PVC molds have been indispensable in this market, but recently they have been squeezed by ABS molds. Their ABC forms are distinguished by their durability, rigidity, wear resistance, and maintainability. Today it is the most the best option in terms of price / quality ratio in the construction of "eurofences".

Molds from ABS plastic.

Samples of textures are laid out on a small pedestal, the gaps between them and the surface are carefully sealed with silicone sealant so that bubbles do not form in future forms. All surfaces must be treated with a separator so that the mold can then be easily removed without damage.

Shape fill with wood texture.

The filling material for the matrix can be one-component or two-component. When preparing a two-component solution, you must strictly follow the instructions, stir the material with a low-speed drill or manually, so that air bubbles do not get into the material. The life time of the fluid material before the onset of gelation is 10-15 minutes, during which it is necessary to fill in the matrix for the mold.

Mixing of the composition must be done at low speeds.

To obtain a large product, polyurethane is carefully poured onto the matrix from one corner. It is necessary to ensure that the material spreads evenly over the plane. To do this, from the side of the pouring, you can slightly raise the stand, and when the material spreads over the entire surface, level the horizontal again. Open surface casting is most often used for the manufacture of flat products with a small height difference. This is the simplest form of molding.

Open shallow fill.

There is another method used for small items. The model is rigidly installed in the formwork. Using a soft brush, the mixture is applied to the model to draw the relief and "distill" the air. The mass is poured in such a way that the thickness of the future form is 10 mm. After hardening, the form should be allowed to stand for two days so that its edges do not fall over. Polyurethane has memory and retains its shape in the first 48 hours. If during this period the form bends, then it will then remain so.

Ready "stone" form.

The main advantages of an open fill:

simplicity,
the ability to see air inclusions.

There is one more fill method - closed. To work with this method, a casing is poured, which ensures the manufacture of a thin uniform shape. This method is more laborious, but it produces forms of higher quality, thinner, which can be removed by rolling.

Pallet manufacturing

In the manufacture of pallets for large products, the supporting elements of the frame are adjusted neatly to the shape and carefully fixed on the pallet, eliminating the appearance of gaps. In the manufacture of non-removable pallets of corrugated or irregular shape, a rigid lateral tight-fitting bottom support is required, which can be performed using polyurethane foam. These shapes have precise surfaces of high quality. The products will have a clean surface like marble or granite. And if coloring pigments are added to concrete during manufacture, then you can achieve a visual imitation of natural materials.

Making molds for an eurofence is not a particularly difficult task. Your reward will be a durable and reliable concrete fence.

Fence panels

Among the owners country houses, cottages and townhouses, decorative concrete fences are very popular. The demand for such products is so great that many are beginning to consider the production of concrete fences as one of the main ways to earn money.

In our article, we will try to describe the technological process of the production of cast cement fences as easily as possible, and also dwell on several nuances, on the observance of which the quality of the finished product depends.

Necessary equipment and raw materials

When planning the organization of the production of cast sections for concrete fences, it is necessary to attend to the presence of three elements:

Manufacturing technologies.
Equipment.
Raw materials for production.

And if there is enough information regarding technology (including this material itself, as well as the video in this article), then serious investments will be required to purchase tools and raw materials.

What equipment for the production of reinforced concrete fences is included in the minimum set? In order to start the manufacturing process, we need:

Vibrating table - concrete fence making equipment

A set of matrix forms. It includes both forms for the slabs themselves and forms for the posts. Different production technologies involve the use of forms different types, therefore, we will dwell on their construction in more detail in the corresponding section.
Vibrating sieve. Designed for cleaning cement, sand, etc. from impurities. The cleaner the raw materials used, the higher the mechanical and aesthetic characteristics of the fence will be.
The shaping vibrating table is a key piece in the entire equipment portfolio. This is due to the fact that it is by vibration casting that we remove air bubbles from the panel, which means we provide it with the necessary strength.
As for the concrete mixer, experts recommend using forced models to improve product quality.

Vibrating sieve

Also, to organize the process of making cement fences, we need a room. The optimal area is about 200 m2, since a significant space is required for drying finished products.

Instant demoulding

Materials used

The concrete panels used for the construction of fences are produced by vibro cassette casting. In this case, two different technological schemes can be used: "exposure" and "instant stripping". For an inexperienced reader, the difference in these technological schemes is small, but at the same time the final product turns out to be very different in quality and performance.

Panel making mold

"Instant stripping" involves casting a specially prepared mixture into high-strength dies. At the same time, for effective work it is necessary that we have at our disposal a sufficient number of stripping pallets.

Note! The required number of pallets can be calculated by multiplying the planned daily number of slabs cast by two.

As a rule, for the production of fencing slabs using this technology, fiberglass matrices with a metal frame. Such forms for the production of concrete fences have a sufficient margin of safety and weigh more than 50 kg.

Preparation of mortar in a concrete mixer

For the production of fences in this way, a special potting mixture is used:

Concrete grade M300 and higher.
The water-cement ratio is 0.35.
Filler - crushed stone no more than 5 mm.

If the production of panels for fences is planned, then the use of plasticizers is mandatory. You can also use fillers that speed up the curing process and give the finished panel different shades.

For lubrication of forms, you can use such compositions as "Lerossin", "Separen" and similar. It is also possible to make homemade lubricating mixtures based on mineral oils with used engine oils, fuel oils or diesel fuel, but the surface quality of the plate in this case is rather low.

Sequence of operations

The production process of fences using the "instant demoulding" technology takes place according to the following scheme:

A form is installed on the vibrating table, switched on in the operating mode. The mold must be pre-cleaned and oiled to avoid adhesion of cement and the formation of a defective surface.
The mixture of the required consistency is poured into the mold. The excess mixture is cut using a long rule flush with the sides of the form.
Reinforcement mesh made of rods is laid on the pouring surface, after which, under the influence of vibration, it is pressed into the depth of the plate. Try to position the reinforcement as close to the center of the part as possible.
When the sealing process is complete (as evidenced by the absence of bubbles on the pouring surface), the table is turned off.
Two workers raise the shape and lay out the finished section of the fence onto the stripping pallet.
The form is cleared of concrete residues, rinsed and lubricated for the next fill.

Drying the product

Making a concrete fence with your own hands by stripping on a pallet involves obtaining a fairly cheap material, which, however, does not have high aesthetic characteristics.

If you are more impressed by the high-tech production of concrete fences, then you should consider the technology of exposition casting.

Exposition casting

Differences in technology

In general terms, the technologies of instant demoulding and exposure casting are similar, but if you plan to make concrete fences with your own hands, then you should carefully study all the differences in the operations performed.

And the main one of these differences is the fact that the process of curing takes place directly in the form itself. The front surface of the slab is formed at the point of contact of the material with the counter surface of the matrix, which means that only high-quality forms for the manufacture of concrete fences should be used for exhibition production.

PVC matrix

As a rule, today, for this purpose, injection matrices are used, made either from PVC or from ABS plastic:

Polyvinyl chloride (PVC) molds are made of material with a thickness of 0.75 - 1.2 mm. The smooth inner surface makes it possible to produce decorative panels for fences, as well as posts, curbstones, monuments, etc. The strength of PVC molds is sufficient for working with concrete mix, and the durability is about 50 cycles.

Decorative matrix

Note! Pallets for working with PVC casting matrices should be made with the most accurate dimensions, excluding the slightest deformation of the plate. This is due to the fact that thin walls made of polyvinyl chloride have practically no bearing capacity.

ABS plastic (acrylonitrite - butadiene - styrene) is superior to PVC primarily in terms of durability. Acrylonitrite matrices are capable of withstanding up to 200 pouring-stripping cycles, so if you plan to make concrete fences with your own hands on an industrial scale, then you should choose ABS.
The thickness of the polymer sheets used in this case is 2.2 mm. This allows the use of less durable (and therefore lighter) pallets. At the same time, the price of ABS is not much higher than the cost of a PVC form, therefore, if possible, this material should be chosen.

ABS injection mold

Advice! Forms from acrylonitrite sheet are produced by the method of corner gluing, therefore, when cleaning and lubricating, it is worth monitoring the state of the glue seams. The appearance of gaps or cracks in the corners is the first sign that the matrix will soon fail.

Exposure casting process

Making a concrete fence with your own hands using the exposure method is also quite simple. The instruction describing the sequence of our actions is given below:

Of durable wooden beam with a cross section of up to 60 mm we make a stretcher pallet. The design of the stretcher should exclude the displacement of the form during pouring and stripping.
For panels of complex shape with decorative elements, foam plastic can be used in the manufacture of a pallet, polyurethane foam etc. These materials are designed to support the bottom of the die and keep parts safe from shifting and crushing.

Distribution of solution in the matrix

We place the matrix in a wooden pallet, grease it and serve it on a vibrating table. For processing inner surface experts recommend using the K-222 stripping compound, because, due to its characteristics, it almost completely eliminates contact between plastic and the casting mixture.
We serve the filling mixture into the greased form, after which, as a rule, we align it along the edge.
We recessed the fittings into the filling, after which we carry out vibration compaction until the formation of bubbles on the surface stops.
We remove the stretcher with filling from the vibrating table and transport it to the drying place. From the moment of completion of the compaction to the removal of the formwork, at least a day must pass. At the same time, the casting mixture is constantly inside the mold, and the fence acquires the required configuration.

Photo of the finished product

With strict adherence technological process the result is a flat and smooth concrete fence section, the surface of which looks very attractive even without additional processing. The introduction of a decorative filler or pigment into the composition of the potting mixture allows you to create imitations of granite and marble with your own hands.

Making a concrete fence with your own hands is a difficult and rather expensive task. At the same time, if you follow the instructions scrupulously, then the quality of the finished product should be at its best. This means that due to high demand, your investment will pay off pretty quickly.

They are very popular among the owners of country houses, cottages and townhouses. The demand for such products is so great that many are beginning to consider the production of concrete fences as one of the main ways to earn money.

Necessary equipment and raw materials

When planning the organization of the production of cast sections for concrete fences, it is necessary to attend to the presence of three elements:

Manufacturing technologies.
Equipment.
Raw materials for production.

What equipment for production is included in the minimum set? In order to start the manufacturing process, we need:

Vibrating table - concrete fence making equipment

A set of matrix forms. It includes both forms for the slabs themselves and forms for the posts. Different production technologies involve the use of different types of molds, therefore we will dwell on their design in more detail in the corresponding section.
Vibrating sieve. Designed for cleaning cement, sand, etc. from impurities. The cleaner the raw materials used, the higher the mechanical and aesthetic characteristics of the fence will be.
The shaping vibrating table is a key piece in the entire equipment portfolio. This is due to the fact that it is by vibration casting that we remove air bubbles from the panel, which means we provide it with the necessary strength.
As for the concrete mixer, experts recommend using forced models to improve product quality.

Also, to organize the process of making cement fences, we need a room. The optimal area is about 200 m 2, since a significant space is required for drying finished products.

Instant demoulding

Materials used

Manufactured by vibrocassette casting. In this case, two different technological schemes can be used: "exposure" and "instant stripping". For an inexperienced reader, the difference in these technological schemes is small, but at the same time the final product turns out to be very different in quality and performance.

Note! The required number of pallets can be calculated by multiplying the planned daily number of slabs cast by two.

As a rule, fiberglass matrices with a metal frame are used for the production of fencing slabs using this technology. Such forms for the production of concrete fences have a sufficient margin of safety and weigh more than 50 kg.

For the production of fences in this way, a special potting mixture is used:

Concrete grade M300 and higher.
The water-cement ratio is 0.35.
Filler - crushed stone no more than 5 mm.

If the production of panels for fences is planned, then the use of plasticizers is mandatory. You can also use fillers that speed up the curing process and give the finished panel different shades.

Sequence of operations

The production process of fences using the "instant demoulding" technology takes place according to the following scheme:

A form is installed on the vibrating table, switched on in the operating mode. The mold must be pre-cleaned and oiled to avoid adhesion of cement and the formation of a defective surface.
The mixture of the required consistency is poured into the mold. The excess mixture is cut using a long rule flush with the sides of the form.
Reinforcement mesh made of rods is laid on the pouring surface, after which, under the influence of vibration, it is pressed into the depth of the plate. Try to position the reinforcement as close to the center of the part as possible.
When the sealing process is complete (as evidenced by the absence of bubbles on the pouring surface), the table is turned off.
Two workers raise the shape and lay out the finished section of the fence onto the stripping pallet.
The form is cleared of concrete residues, rinsed and lubricated for the next fill.

Making a concrete fence with your own hands by stripping on a pallet involves obtaining a fairly cheap material, which, however, does not have high aesthetic characteristics.

If you are more impressed by the high-tech production of concrete fences, then you should consider the technology of exposition casting.

Exposition casting

Differences in technology

As a rule, today, for this purpose, injection matrices are used, made either from PVC or from ABS plastic:

Polyvinyl chloride (PVC) molds are made of material with a thickness of 0.75 - 1.2 mm. The smooth inner surface makes it possible to produce decorative panels for fences, as well as posts, curbstones, monuments, etc. The strength of PVC molds is sufficient for working with concrete mix, and the durability is about 50 cycles.

Note! Pallets for working with PVC casting matrices should be made with the most accurate dimensions, excluding the slightest deformation of the plate. This is due to the fact that thin walls made of polyvinyl chloride have practically no bearing capacity.

ABS plastic (acrylonitrite - butadiene - styrene) is superior to PVC primarily in terms of durability. Acrylonitrite matrices can withstand up to 200 pouring-stripping cycles, so if you plan to make concrete fences with your own hands on an industrial scale, then you should choose ABS.
The thickness of the polymer sheets used in this case is 2.2 mm. This allows the use of less durable (and therefore lighter) pallets. At the same time, the price of ABS is not much higher than the cost of a PVC form, therefore, if possible, this material should be chosen.

Advice! Forms from acrylonitrite sheet are produced by the method of corner gluing, therefore, when cleaning and lubricating, it is worth monitoring the state of the glue seams. The appearance of gaps or cracks in the corners is the first sign that the matrix will soon fail.

Exposure casting process

Making a concrete fence with your own hands using the exposure method is also quite simple. The instruction describing the sequence of our actions is given below:

We make a stretcher pallet from a durable wooden beam with a cross section of up to 60 mm. The design of the stretcher should exclude the displacement of the form during pouring and stripping.
For panels with complex shapes with decorative elements, foam plastic, polyurethane foam, etc. can be used in the manufacture of a pallet. These materials are designed to support the bottom of the die and keep parts safe from shifting and crushing.

We place the matrix in a wooden pallet, grease it and put it on a vibrating table. For the treatment of the inner surface, experts recommend using the K-222 stripping compound, since, due to its characteristics, it almost completely eliminates the contact between plastic and the casting mixture.
We serve the filling mixture into the greased form, after which, as a rule, we align it along the edge.
We recessed the fittings into the filling, after which we carry out vibration compaction until the formation of bubbles on the surface stops.
We remove the stretcher with filling from the vibrating table and transport it to the drying place. From the moment of completion of the compaction to the removal of the formwork, at least a day must pass. At the same time, the casting mixture is constantly inside the mold, and the fence acquires the required configuration.

With strict adherence to the technological process, the result is a flat and smooth section for a concrete fence, the surface of which looks very attractive even without additional processing. The introduction of a decorative filler or pigment into the composition of the potting mixture allows you to create imitations of granite and marble with your own hands.

Decorative concrete fence with stacked posts

This is what concrete sections look like for a type-setting concrete fence.
The decorative fencing sections are made up of horizontal narrow panels (about 50 cm) stacked on top of each other. Thanks to the individual sections, you can create an exclusive fence by assembling the fence panels in different ways. It can be a solid canvas under a stone, brick, wood or a fence with openwork carved inserts.

Advantages and disadvantages of a decorative fence

Among the positive qualities of sectional fencing, it is worth noting:

It is difficult to find flaws in such a fence, but it is still possible:

Concrete fences are expensive versus wood or.
Another disadvantage is the likelihood of purchasing low-quality products from unscrupulous manufacturers.

A concrete fence will be truly reliable and durable if high quality raw materials are used for its production and a responsible approach to the production process.

Shape and pattern for sections of concrete fence

To be sure that the technology was followed at all stages of production, fence panels for summer cottages can be made independently.

Forms for decorative fences

Decorative fence panels are produced by vibration casting from high-quality Portland cement, refined sand, gravel, and reinforcement. Often dyes are added to the cement mixture to give the finished products different colors.

Types of forms for decorative sections

Dies for concrete panels can be made of various materials:

Polyvinyl chloride (PVC)

Polyvinyl chloride forms are presented in a wide range and have a good service life (they can withstand about 100-150 production cycles).

Production of decorative fences

The process of making decorative sections is not complicated, the main difficulty lies in preparing the necessary materials and tools.

Necessary equipment

forms for concrete sections;
concrete mixer;
vibrating table for forming concrete products;
vibrating sieve for cement and sand;
drying trays for finished sections.

It looks like a vibrating table for casting concrete products

Choosing a fence for a summer cottage, each owner tries to find the most durable and durable structure that does not need to be repaired and tinted regularly.

At the same time, I want the cost of a fence for a summer residence to be affordable for a home budget, and its installation did not require the use of special lifting equipment. All these requirements are met by concrete sectional fences - easy-to-assemble and reliable structures, which today can be found at every summer cottage.

It is not difficult to make a concrete fence for a summer residence on your own, since all the necessary technologies and materials are presented on the market of enclosing structures.

IN soviet time the only option for such a fence was a solid reinforced concrete slab - a heavy and inexpressive structure, more suitable for industrial enterprises and warehouses.

Nowadays, the most popular fences are made from small 2-meter sections, which are installed in the grooves of concrete pillars. The modular principle of their construction allows the owner to easily select not only the height, but also the appearance of the fence. For this, two types of concrete sections are produced - solid and openwork (transmitting light).

There is a huge variety of options for the texture of such concrete slabs, which allows you to build a fence that imitates brickwork, a natural stone or surface wooden board... The top of a sectional concrete fence is usually finished decorative section curvilinear outline.

Sectional fence manufacturers are trying to give their products original view and hide visible longitudinal seams.

To do this, they make sections in which the seam goes along the uneven joint of the "masonry". As a result, a decorative concrete fence looks like a single monolith made of wild stone. The pillars connecting the slabs are also not disregarded and are cast in forms that imitate the volumetric stone texture.

In addition to the fence sections, in which only one side has a decorative texture, today the market sells double-sided fence plates. A fence made of them looks equally beautiful, both from the outside and from the inside.

The cost of sectional concrete fences is fully consistent with their durability and strength. In terms of a 50-year service life, such a summer cottage fence will cost no more than a metal profile, mesh or picket fence.

Estimated prices for a standard section 2 meters long and 0.5 meters high are in the average range from 350 to 600 rubles.

For a smooth pillar, designed for the installation of four panels (total height 2 meters), manufacturers ask from 600 rubles. Exactly such a pillar, but with a textured surface, will cost you an average of 1400 rubles.

We make a sectional concrete fence with our own hands

The simplicity and relatively low cost of the cast concrete technology, as well as the availability of the necessary equipment on the market, make affordable option self-made intake sections.

It should be noted that the cost of molds and vibrating table will pay off only if the length of the fence is at least 120 meters (plot area from 8 acres).

To get started, you need to purchase three or four one-sided forms for concrete fences made of PVC or fiberglass. Depending on the quality and thickness of the plastic, their cost ranges from 2000 rubles. for 1 piece The cost of a mold for 2.8 meters long grooves ranges from 3500 to 4200 rubles.

It is impossible to make high-quality fence concrete blocks and pillars without use. On it, the concrete mix is \u200b\u200bwell compacted and fills all the elements of the textured surface of the form. The price of a vibrating table is on average from 23 to 37 thousand rubles.

In addition, making a concrete fence requires the use of a concrete mixer. It will be needed not only for preparing a casting mixture for molds, but also for mixing concrete to embed pillars.

Stages of installation of a concrete sectional fence

A team of three can handle this work, since the installation of concrete sections in the guide slots of the posts does not require the use of a crane.

Installation will require the following tools and materials:

Shovel and crowbar;
Building level and cord;
10-16 wooden template strips (each 201 cm long). They are necessary to accurately record the distance between concrete pillars when installing them.

If the installation of a type-setting concrete cottage fence will be carried out on an area with a large slope, then a level will be needed to accurately determine the height of the fence steps.

A sectional concrete fence with your own hands is mounted in two stages.

The first includes the following operations:

A lighthouse cord is stretched along the perimeter of the fence at a height of 0.4-0.5 m from the ground;
Pits are dug to the depth of the concreting of the pillars with a step of 2 meters;
A pillar is lowered into each pit, leveled with a level and fixed with large rubble or brick fragments;
A wooden rail-template is inserted into the groove of the installed post, and its second end is abutted against the groove of the next fence post.
The building level, which is applied to the template rail, determines the depth of the pillars and, if necessary, pours soil under them or further deepens the pit.
After making sure that the distance between adjacent posts in the upper and lower parts is the same (the template rail does not fall into the groove, but is kept in it), the posts are fixed in the pit and proceed to the second stage of installation.

A concrete mixture of sand, fine gravel, cement is kneaded in a ratio of 3: 2: 1 and all pits are poured with it.
After concreting with a level, the verticality of the pillars is checked again.
Installation of fence panels in summer period can be started 1 day after concreting, and in spring or autumn after 3-4 days.

Often the installation of a concrete fence is completed by painting the slabs. To do this, use a concrete primer and facade paint with the addition of the desired color pigment.

However, this work is not mandatory, since even an unpainted concrete fence can withstand the effects of atmospheric moisture and temperature extremes.

Concrete Fence Business: How to Start? Form for the production of concrete fences Equipment for the production of concrete fences

For the manufacture of concrete fences are used:

Concrete fence manufacturing technology

How to determine the quality of concrete?

Quality parameters:

Technology for the production of concrete fences and pillars

Types of forms, their advantages and differences

Polyurethane

PVC

Fiberglass

ABS plastic

What to choose?

Manufacturing technology of concrete sections

What are the fence sections

Advantages and disadvantages of a decorative fence

Forms for decorative fences

Types of forms for decorative sections

Polyvinyl chloride (PVC)

ABS plastic

Polyurethane

Fiberglass

Production of decorative fences

Necessary equipment

Raw materials and supplies

Stages of making a decorative fence

Instant demoulding

Features of exposition casting

What does a concrete decorative fence consist of?

Molds for casting

How to make a die for a mold

Pallet manufacturing

Necessary equipment and raw materials

Instant demoulding

Materials used

Sequence of operations

Exposition casting

Differences in technology

Exposure casting process

Necessary equipment and raw materials

Instant demoulding

Materials used

Sequence of operations

Exposition casting

Differences in technology

Exposure casting process

Advantages and disadvantages of a decorative fence

Forms for decorative fences

Types of forms for decorative sections

Polyvinyl chloride (PVC)

Production of decorative fences

Necessary equipment

We make a sectional concrete fence with our own hands

Stages of installation of a concrete sectional fence

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