Manufacturing technology of concrete fences. Business idea: production of concrete fences. Types of forms for decorative sections

Fence concrete fence adjoining territory - this is not only reliable protection, but also an additional decoration of the architecture of the house. Today, concrete fences are considered one of the most reliable and durable, and you can make them yourself.

What types of concrete fences are there

First of all, they are distinguished by purpose and design, and secondly, by manufacturing and installation technology.

The functional task of the fence is to enclose the territory, which also contains a decorative meaning. So, in the vicinity of a wooden log house, this fence will look out of place, but the architecture of a stone building will harmoniously combine with concrete panels or bricks.

Nowadays, fences are not only constructed from flat-shaped prefabricated concrete panels - they can be made independently using various forms... In addition, a decorative fence can imitate natural material, have different colors and a certain style.

Possible options in the photo

A stone structure on a solid foundation will protect the local area from prying eyes The hollowness of concrete blocks allows the use of a large number of elements due to their low weight The simplest of the fences is monolithic with one decorative side Embossed inlays provide a refreshing highlight The double-sided fence can be easily used on the personal plot The contrast is created by the support pillars in dark color, echoing the color of the roof of the house. Both the design itself and the finish are expensive, but justify their operational life

Varieties of fences

These include:

1. Monolithic.
2. Typesetting.
3. Decorative.

Table: advantages and disadvantages of concrete fences

Fencing type	pros	Minuses
Monolithic	Strength, durability, large size, the ability to decorate surfaces with painting	Large weight, non-lifting unit (the use of hoisting machines is required), the need for a solid foundation
Self-contained	The height of the finished blocks is up to 3 m, ease of assembly due to the one-piece panel construction, the possibility of installation without a foundation	Heavy weight (up to 2.5 t)
Typesetting	Ease of assembly, the presence of a decorative (outer) side, the ability to install on a foundation and without it. Decoration fence, standard sizes. Can be bilateral	The need to install additional supports-pillars for fixing the panels, the relatively large weight and the need to use a crane
Decorative	Least weight, variety decorative species, the possibility of using materials with imitation of any surface, ease of installation and the possibility of arranging a fence without the involvement of special equipment	Higher cost (with additional surface decoration)
Blocky	Light weight due to the hollowness of the blocks, no need for additional installation of pillars	Necessary requirement: laying blocks on cement, followed by decoration or plastering of the surface and the obligatory arrangement of a solid foundation; the cost is higher than for a fence made of type-setting panels

Monolithic fences are used, for the most part, by large enterprises, institutions and even guarded parking lots - organizations for which the protective function of the fence is primarily important. Such fences have a rough external texture and are panel. They cannot be stacked on top of each other, as a constructor, since the panels are heavy. A prerequisite is the construction of a solid foundation.

Recently, monolithic reinforced concrete slabs have been installed on the sites, thanks to which the fence is called independent. Characteristic feature a wide horizontal base for installation is mandatory; in some cases, self-standing fences can be installed with spikes on the "glass".

A fence is called a stacked fence, consisting of several plates. Type-setting plates have both a different texture and a decorative side, and one of the parts of the sections may differ from the other - as a rule, these are the upper rows of the fence.

One section can contain up to four assembly panels installed in grooves. For a type-setting concrete fence, it is also necessary to construct supports - special pillars, to which the sections will be attached.

When installing a type-setting type of fence, it is necessary to accurately calculate the step between the supports, and also firmly fix them.

Most owners of private houses use concrete euro panels instead of conventional panels, which are lighter and more convenient to install. The most common size of the Europanel is 2.0x0.5x0.12 m. In addition, typesetting panels are often produced double-sided - having the same surface appearance on both sides.

Decorative fences include panels erected from separate sections.

Decorative fences can imitate textures such as:

• wood;
• brick;
• granite or marble;
• cobblestone and rough stone;
• metal forging.

How to make a concrete fence with your own hands

Fences can be installed from standard panels purchased on the construction market. And you can make it yourself - "for yourself". Do-it-yourself construction of a protective structure will be an advantage in the case when the owner wants to see a non-standard design on the site, harmoniously combined with the general architecture of the house and the adjacent territory.

Preparatory work

First you need to choose a material for mixing the solution. For this you will need:

1. Cement M400 or M500.
2. Fine crushed stone - 19–20 mm.
3. The sand is coarse.
4. Water.

By mixing them in a certain proportion, a solution is obtained that must be used immediately - otherwise it will harden. The construction time is four weeks.

It should be remembered that the more sand in the mortar, the lower the concrete strength will be.

Table: recipe for the preparation of concrete mortar

For the manufacture of concrete blocks, a little plasticizer is added to the solution - it will give more plasticity to the raw material and allow you to create the required shape for the blocks. Water is added to the solution until the texture of a viscous thick sour cream.

The mortar can be mixed in a large trough, but the presence of a concrete mixer will speed up the process.

When working with a concrete mixer, crushed stone is first loaded into it, filled with a small amount of water - so that the cement does not stick to the blades of the inner drum, and only then cement and sand.

Preparation of tools and forms

The mixture for the mortar is already mixed in the concrete mixer, now it remains to prepare the tools for work:

• spatula, level;
• forms for solution;
• steel reinforcement (with a section of 4 mm for a fence and 8 mm for pillars).

If possible, it is advisable to install a vibrating table for the duration of the fence at the construction site - for compacting concrete forms. The molds for pouring are sold in hardware stores and are rubber, polypropylene, plastic and fiberglass.

Calculation of the number of slabs and concrete for the construction of the fence

If you have already decided on the type, then you can start making plates. For a conventional level fence, you will need removable formwork and mortar. The amount of volume for one plate can be calculated based on the formula:

V \u003d L x H x B, m 3, where V - volume, m 3; L - length, m; H - height, m; B - width, m.

Thus, for one slab measuring 1.6x1.5x0.15 m, the volume of the solution will be 0.36 m 3. The width of one slab of a homemade fence should be at least 150 mm.

The number of slabs will depend on the perimeter of the fenced area. It should be remembered that the total length of the fence also includes the size of the support posts, the cross-section of which is 300x300 mm.

Again, for an area of \u200b\u200b36 m2 (6.0x6.0 m), 12 slabs will be needed:

N \u003d P / L \u003d (2 x (a + b) - 0.3x16) / 1.6, pcs, where P is the perimeter of the enclosed area, m; a and b - sides, m; 0.3 - the length of one pillar, m; L is the length of one slab, m.

The number of pillars for the entire perimeter is 16 pieces, obtained from the calculation (a-3xL) / s, where a is the side of the site \u003d 6.0 m; s - 0.3m - post length, m.

There are 4 posts on one side of the fence, therefore, a total of 16 pieces must be supplied.

The total volume of the mortar on the slabs will be at least 0.36m 3 x 12 pcs \u003d 4.32m 3.

On the base for the slabs (although it is preferable to arrange a strip foundation) it will take a little less: with dimensions of 1.6x0.5x0.3 m, the volume of the solution is V \u003d 0.24m 3. For slabs in the amount of 12 pieces, concrete will be consumed V \u003d 0.24x12 \u003d 2.88m 3.

Total total volume of concrete solution will be 4.32 + 2.88 \u003d 7.2m 3

The width of the foundation for the fence should be twice the width of the slab.

If the choice fell on a concrete fence made of ready-made forms, then everything is easier. You just need to follow the instructions for making the amount of solution for a particular form.

Ready-made device

• The concrete mix is \u200b\u200bloaded into a concrete mixer.

• A pouring mold is placed on a flat surface, oiled or special compositionpreventing sticking of the frozen solution.
• Reinforcement is placed in the mold - for the strength of concrete adhesion.

• After laying the reinforcement, the mortar can be poured. After filling the form to the brim, the concrete should be leveled with a spatula.

• After drying, the finished product is removed and placed until completely dry - under a canopy. After making the forms of the required number, they can be installed on the foundation, fastening the sections together using support pillars.

Video: device of a concrete fence from ready-made forms

Device with formwork

With an independent device of a fence without using a form, the whole process comes down to the fact that instead of ready-made forms, you will need to arrange a removable formwork and a foundation.

The foundation for the fence should be wider than the main structure.

This is done as follows.

First, a solid (preferably a strip) foundation is constructed for the future fence, for which a ditch with the required width is dug, a sand cushion with a layer thickness of 20-25 cm is arranged there.

The layer is then poured with concrete mortar and left until its brand strength gains - usually for a month. Periodically, it is advisable to wet the concrete structure with water for greater strengthening.

While the foundation is gaining its strength, it is possible to prepare material for removable formwork - boards, boards and props. The formwork is set to the width of the planned fence, fixing it on both outer sides.

The fence can be built both separately from a standing house and for a fence adjacent to the house

Don't forget about structural reinforcement!

After cooking concrete mortar poured into a homemade mold from the formwork to the initial layer height of 20–25 cm, then carefully tamp and add more mortar to the same layer height. The number of layers can be different - it is important that the pouring of the fence into the formwork takes place on the same day, otherwise even a newly built structure can crack.

The height of the fence can be arbitrary - it will depend on the height of the formwork. The poured solution is allowed to settle for at least a day, after which the formwork is removed and transferred to another area.

This erection system is the simplest. The complexity of the work lies in the preparation of the solution and the device of the formwork structure.

Finishing the finished building

The fence is delivered and needs the final touch - decorative finishing, which include:

• painting;
• decorative plaster;
• brick and clinker tiles;
• laying of decorative and natural stone.

The most affordable and easiest type of decoration is painting the fence in your favorite color. True, for this you have to prepare the surface - grind, repair possible cracks, level and prime.

Concrete paint manufacturers guarantee an 8-year service life, which is quite good and inexpensive for a concrete fence. Another advantage of the paint is its use not only on a flat, but also on a relief surface - where fences are inlaid, with a decorative surface.

It is necessary to paint the surface - so that the fence lasts as long as possible, is protected from moisture, and is in harmony with the general architecture of the house.

The choice of paints today is great, but you should choose from those that have frost and moisture resistance, resistance to temperature extremes and ultraviolet radiation. All the requirements are met by ordinary facade paint - acrylic, latex, silicone. An important condition: the paint must have a low vapor permeability coefficient.

The amount of paint is purchased at the rate of 1: 300 - 300 ml of paint will be required per 1 m 2. However, the final volume will depend on the type of surface - the more embossed, the more paint will be needed.

As for the color solutions, the most successful are considered to be close to natural - beige, green, brown, pale blue or gray. The choice of these shades will be in harmony with the planted plants, highlighting their natural beauty.

Variegated colors for coloring the fence are unacceptable - a couple of shades are enough. If the fence is embossed, then individual elements can be highlighted with a contrasting color or the same shade as the fence itself, only a few tones darker.

In addition, correctly applied paint can imitate wood or sandstone - for this, a foam rubber sponge is used, dipping it into paint different colors - dark and light. The paint is applied to a pre-primed surface in order for the layers to adhere better to each other.

If you want some specialties, then you can use decorative plaster. As a rule, high quality material is selected, and in this case, you can even use Venetian plaster - it is of better quality, lasts longer, is not afraid of dampness and temperature extremes. It can imitate marble - then the surface is smooth.

You can also use marble or granular chips.

The disadvantages include the laboriousness of the process - for example, the same Venetian plaster will have to be applied at least 5 times, and for better adhesion to the concrete surface, manufacturers advise to apply up to 12 layers.

The third type of finish is brick or clinker tiles. Here, the laboriousness of the process lies in the ideal leveling of the main surface - otherwise, the finish will not adhere well to the concrete and will soon fall off. Therefore, embossed panels, type-setting fences and sections with a decorative pattern cannot be used.

Stone trim is the most expensive type of fence cladding, but the most durable. Before laying, the surface should be thoroughly cleaned, sanded and primed, as well as reinforced - so that the material holds as long as possible.

Of the pluses of finishing with a stone, one can note the luxurious appearance and strength of the fence, of the minuses - the cost and laboriousness of work, a large load on the foundation. Therefore, if it is planned to install a concrete fence with subsequent stone finishing, the type of foundation will have to be selected at the stage of preparatory work.

Video: how to make a concrete fence with your own hands

The construction of a concrete fence for fencing the local area is a laborious process, but the result is worth it: with its durability and strength, such a structure will last much longer than a fence made of wood or corrugated board, will require less costs in preparing materials and annual maintenance.

• Raw materials and supplies
• conclusions
• The financial aspect of organizing the production of decorative fences
• Paperwork
• Choice of tax regime

Due to the rapid growth of low-rise construction in Russia, the demand for decorative fences and concrete structures has increased. With decorative concrete fences can beautify the meager design of almost any modern building.

Why are more and more private clients now choosing to install concrete fences? There are several reasons for this:

1. Decorative concrete fences are cheaper than metal, brick or wood fences;
2. They are more durable and not subject to severe weathering;
3. Concrete fences are mounted as soon as possible;
4. Can be repainted in any color. They hold the paint for a long time - it is necessary to re-paint it only after 8 years.

This segment is attractive for business because, firstly, there is no serious competition - decorative fences, as a rule, are made only for individual orders... Secondly, the current price for these products is clearly overstated, which is due to the absence of serious manufacturers of the product on the market.

If we start mass production of concrete fences, there is a chance to firmly occupy a niche and fully satisfy the growing demand for the product.

What equipment to choose for the production of concrete fences

The minimum set of equipment for the production of decorative fences includes:

1. Vibration table for forming concrete structures with two electric vibration motors;
2. Concrete mixer (concrete mixer);
3. Vibrating sieve for sifting sand and cement;
4. A set of forms for the manufacture of panels and posts;
5. Drying trays for finished products.

The most expensive item of expenses when starting a business is purchasing a set of forms. Forms are divided into two types: forms for panels (blind, openwork, double-sided) and forms for posts. Since the fence is of different thickness, height, design, etc. to create a wide range of concrete structures, a variety of forms themselves are needed. Plus, to produce a normal volume in one working cycle, up to 5 molds of the same type are required. Thus, the total number of molds, even in a small business, can be over 50 pieces.

The cost of one form for a panel, on average - 15 thousand rubles, a form for poles - 8 thousand rubles. a piece. Thus, the total cost of purchasing only one form will be about 500 thousand rubles.

In addition to molds, production will require a vibrating sieve, concrete mixer and vibrating table. A mechanical vibrating sieve costs around 15 thousand rubles. The vibrating sieve is designed for cleaning sand, cement and other bulk materials from weed particles. The number of such machines depends on the planned production volume. If the volumes are not large, one or two pieces will be enough.

The price of concrete mixers depends on the capacity of the apparatus. In terms of power and productivity, concrete mixers are divided into gravity and forced. The first option refers to portable models and is used in small industries. Gravity concrete mixers do not require high voltage (380V) connection and do not consume a lot of electricity. The price range for such devices is from 9 to 50 thousand rubles. If the enterprise requires large production volumes, then portable concrete mixers are purchased. They are much more expensive than other models - from 60 to 500 thousand rubles. At the same time, they have increased productivity. Often they require installation on a foundation.

For pouring and compacting concrete in plastic molds, you will need a shaping vibrating table, and for removing the finished concrete fence, a stripping vibrating table. The cost of both is from 15 to 18 thousand rubles. The total cost of purchasing two vibrating tables is 30-36 thousand rubles.

Thus, the total cost of purchasing equipment will amount to at least 600 thousand rubles. The total investment for starting a business reaches 1 million rubles, or even more.

Which room to choose for the production of concrete slabs

The total area of \u200b\u200bthe premises for starting production is at least 300 m2. The minimum size of the production area is 50 m2. The recommended area for production is 250 m2. In addition to production space, a warehouse is required for inert materials, with an area of \u200b\u200bat least 50m2; storage warehouse for finished products, also not less than 50m2; a blank section for cutting and welding of fittings and a finished product warehouse. All areas, except for the warehouse, must be heated and connected to the 220V power grid.

According to the requirements of the legislation, production must be located at a distance of at least 150 meters from residential complexes, schools, kindergartens and others social institutions... The ideal location is suburban and industrial areas. The cost of renting a heated room with an area of \u200b\u200b300 m2, depending on the region, will be from 50 thousand rubles per month.

Raw materials and supplies

The main raw material for the production of concrete fences consists of: cement (Portland cement) grade 500-D0; construction sand GOST 8736-93; wire (reinforcement) and various plasticizers designed to speed up the process of concrete setting. One concrete pillar 2m high requires 11 running meters of wire 8mm thick. Also, during direct installation, facade paint is used to give desired color fence.

All raw materials must be of high quality, especially cement. High strength concrete can only be obtained from special cements. Otherwise, you can get poor quality products and, even worse, dissatisfied customers.

Concrete fence production technology

The most widespread technology for the production of decorative concrete fences is the production by vibration casting. This method is considered the most effective in the production of concrete products of small thickness. The products are durable, waterproof, frost-resistant, which has a positive effect on the durability of the fence.

The technological chain of production of concrete fences consists of the following stages:

1. Preparation of concrete mix in a concrete mixer;
2. Loading the concrete mixture into a pre-lubricated mold, which is located on a vibrating table;
3. Compaction and spreading of the concrete mixture in the mold when the vibrator is on. Excess concrete mixture, formed during the laying, is removed from the mold;
4. Laying reinforcement in a section of a concrete fence. The reinforcement frame is laid with the vibrator turned on;
5. Vibrating the concrete mix for 1 minute until the release of excess air stops;
6. Stripping (removing) products from the mold on the stripping table;
7. Putting the mold back on the vibrating table to repeat the cycle;
8. The finished product is transferred to a rack for further storage and giving the required strength. Natural hardening of the product up to 70% of the design strength occurs within 48 hours.

In order for the product to gain the required strength, it is recommended to maintain the room temperature at least +15 gr. The humidity of the room is also important, which should be close to 100%. As a rule, the product can be transported to the construction site after 5 days. Although the full maturity of concrete occurs only after 28 days.

It is possible to reduce the hardening time of concrete fences by installing a drying chamber. After the drying chamber, the concrete product is ready for transportation in less than a day. The purchase of the drying chamber will require additional investments in the amount of 10-20 thousand dollars.

Staff recruitment and remuneration

Depending on the planned production volumes, it will be necessary to hire at least 4 people - 2 people for each shift. In one work shift, 2 workers can produce from 100 to 150 m2 of concrete fence or 10 running meters. Simple production technology does not require hiring highly qualified craftsmen. All the subtleties of production technology can be understood directly in the process of making a fence.

Labor remuneration is the highest cost item in an enterprise. The system of remuneration for such a production is predominantly piece-bonus. The master receives a salary based on the number of products that he makes per shift, for example, 15 rubles per 1 m2.

How much can you earn by making concrete fences

The main customers for such production are private households and organizations, as well as administrative structures. In other words, your client is any building or structure that requires the installation of a normal fence.

Cost of production of one running meter concrete fence averages 400 rubles. The selling price to the consumer is not less than 1200 rubles. Profit from one running meter is 800 rubles. Fences, as a rule, are built with a height of 1.5 meters and a length of several tens of meters. It is not difficult to calculate the total income.

You can make a profit not only through production, but also through the provision of fence installation services. To do this, it is necessary to create a separate team to install fences. The cost of installation depends on the region, and averages 600 rubles / r.m. This, of course, will only increase your profits.

conclusions

When making concrete fences, you shouldn't be limited to one product line. Today, the eyes of customers are more and more focused on other concrete products - garden sculptures, benches, flowerpots, flowerpots, paving stones and so on. It is necessary, if possible, to offer customers a wide variety of products - from standard blanks to unusual design solutions... In this case, you will be provided with orders almost all year round.

Today people have become very scrupulous about the issue of registration of their property. And in this regard, the demand for various original elements of decor and design is increasing every day.

Owners of various cottages, townhouses and just homeowners face some problems of individual design. The fact is that most projects of such buildings are created according to a certain template. Therefore, it is very difficult to stand out in any way among other similar buildings.

Decorative fences made of concrete come to the rescue of modern homeowners. These structures will not only help to fence off your property, but also to give the site individuality. And since the competition in this case is minimal, you can make good money on this. It is the production of fences that we will discuss in this article.

Demand

In fact, manufacturers of forged gratings and similar products are in great competition. But concrete fences have at least three advantages over an iron structure: strength, lower cost, and ease of use.

After all, forged products must be constantly painted, covered with protective enamel (against rust), and in extreme cases replaced due to various types of deformation.

Concrete decorative fences are more unpretentious to use and more durable in design. The number of low-rise buildings is constantly increasing (at least in Russia). But, to the great surprise, the number of companies that provide services for the construction of concrete fences remains relatively small.

And those firms that are engaged in this business are working in a direction that is very different from the topic of this article. From all this, we can conclude that the market does not have enough narrowly focused manufacturers of decorative concrete fences.

Business features

Many people are surprised at one very strange fact, namely, why the production of fences does not attract large enterprises? It is impossible to answer this question unequivocally. Perhaps the owners of large companies do not see any prospects in this business, or the overwhelming majority of firms are simply not satisfied with this work profile.

In any case, the lack of dominance of individual enterprises is even for the best. Due to the lack of large companies in this matter, customers have to turn to small manufacturers who do all the work by hand. And, as you know, the cost of such firms is clearly overstated. To establish a rapid rise, it is necessary to produce goods in large quantities, thereby reducing the cost of one unit of production. Of course, we must not forget about the quality of the buildings (more on this later).

Individuality and wholesales

One of the most difficult moments in the production of a decorative fence is the combination of mass production and the individual characteristics of each product. It is necessary to create the illusion of a personal approach to each client.

It is worth noting that most of them will be middle class people trying to stand out. As you can see, there are enough difficulties in this business, so you need to carefully think over your every step. Everything that was previously dealt only with the general aspects of this case. Now it's worth talking about production technology and special equipment.

Production

During the production of any product, one of the most important points is the careful preparation of the raw materials. The final product will directly depend on their quality. The next most important factor is correct selection necessary equipment. This list includes molds, forming equipment, vibrating sieve, and more. The entire production of fences can be divided into three main stages, which we will talk about further.

First stage

The main constituents of concrete are cement and sand. It is with these elements that production begins. The first step is sifting sand and cement. This is done using special equipment called a vibrating sieve. It is equipped with an electric drive, and the materials themselves pass through cells no larger than 5 mm.

All equipment for the production of concrete fences of this type must be present in several copies. A single production (to order) requires no more than 2 such machines. If you are counting on wholesale, then you will need 3-4 (and maybe more) vibrating sieves. The cost of one such machine depends on the power and the amount of stored resources. The average price is $ 500.

Second phase

The second stage of work consists in mixing the ready-mixed concrete. It is inefficient to carry out this process manually, therefore it is necessary to use automated tools. For this work, the so-called concrete mixers are used, or, as they are called in another way, concrete mixers.

In the global construction equipment market, there is a huge selection of various manufacturers of this device. Here we will not discuss all types of concrete mixers, but only highlight two large categories: gravitational and forced. The first type of concrete mixers is distinguished by its low price. The cost ranges from $ 350 to $ 2,000. Also, many of these devices are portable and do not require industrial voltage for operation.

The most powerful gravitational devices are an exception. Another category of concrete mixers (forced) are much more expensive. Naturally, all other characteristics increase along with the price: the consumed voltage and performance. Also, most forced mixers are stationary, and in some cases an additional light foundation is required. Non-portable concrete mixers are often equipped with a hoist called a skip.

Concrete fence production will speed up significantly with this addition. Skip allows you to pour concrete mix even at a height. The elevator also automates the material loading process, which frees up one manpower (otherwise it would take 1 person to complete this operation). The control system consists of a guide winch and a movable hopper.

Stage three

The fence production process is completed by pouring the finished mixture into a pre-prepared mold. It is at this stage that conventional building materials begin to take on a familiar look.

The very form for a concrete fence must be made without any flaws, including welds and other types of defects.

If these conditions are not met, then a substandard product may end up. This can ruin all the work done earlier. The form for a concrete fence is of two types: deaf and openwork. The price for this equipment is approximately $ 350. When starting a concrete fence business from scratch, molds are practically the most expensive element.

Imagine how many types of this equipment you need to buy to increase the variety of finished tiles. Medium-sized companies should have at least 50 types of forms in stock, plus each type should be in several copies (to speed up the production process).

Business expansion

Every businessman should strive to increase production. In this case, you can offer your customers various additional services. For instance, design decoration (which will correspond to the general appearance of the building), installation (and dismantling of old fences).

Further expansion will only depend on you. You might want to bring your business closer to the middle class by adding various small decorative elements. Or you will serve large companies, making only unique concrete decorative fences. In any case, the scale of your business depends only on you.

Conclusion

As a conclusion, it is worth mentioning the search for employees. This business must be approached with some imagination. In addition to the workers who will make the fences themselves, you need to find a creative designer. In the process of business development, you may need to additionally purchase (or make yourself) various decorative elements: borders, fountains, urns, flower boxes. Concrete fence manufacturing is one of those lines of business that can turn into a gold mine with the right approach.

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Concrete fences: features of DIY production and installation

Concrete as a material for the production of fences has the following advantages:

• convenience in processing (the vibrocasting method allows you to obtain products of any size and shape in a relatively short time); low cost of raw materials (so-called Portland cement is used in production - a mixture of limestone-clay pellets (clinker) and gypsum obtained by firing);

  high strength indicators (fence elements made of reinforced concrete in normal operating conditions serve for at least 20 years).

Typical concrete fence

Manufacturing of fences by vibration casting

The main method of production of concrete fence sections and poles is vibration casting. Its essence lies in the fact that the solidification of raw materials in the form occurs on a special vibrating surface - a vibrating table. Thanks to this technology, bubbles are removed from the concrete mass, which, when solidified, turn into pores and negatively affect the strength characteristics of the finished product.

Vibrating table industrial

It should be noted that vibration casting as a method of producing concrete products is divided into two types:

• instant stripping; exposition casting.

The second type is used when casting textured concrete fence elements: for example, with imitation of wild stone or brickwork. The difference between exposure casting and instant demoulding is that molds with a raised bottom are used for production, the texture of which determines the texture of the front side of the product.

Stages of production of concrete fences

Technological process the outflow of concrete fence elements is as follows:

The first stage is the preparation of the matrix form. In the production of concrete products, molds are commonly used, made either from PVC or from the so-called ABC plastic. Matrices of the second type are more expensive and are very convenient for casting textured fence elements (fence sections such as "braid", "cobweb", etc.). Also, forms made of ABC-plastic last longer than their counterparts from PVC (if the wear life of a PVC-matrix is \u200b\u200bon average 50 cycles, then a matrix made of ABC-plastic can be used for production about 200 times).

The matrix is \u200b\u200binstalled on a vibrating table and lubricated from the inside with a special compound that ensures easy removal of the product after solidification. In production, lubricants Separen and Lerossin are most often used.

The second stage is raw material filling. The vibrating table is turned on and Portland cement is poured into the matrix form installed on it, brought to the desired consistency in a concrete mixer. Surplus raw materials are removed from the edges of the matrix.

Reinforcement cage

The third stage is the installation of the reinforcement mesh. All elements for the fence are made with fittings inside, which allows you to evenly distribute the load of the raw material over the entire area of \u200b\u200bthe product. The armature is placed on the surface of the future product and "goes" into it under the influence of vibration.

The concrete hardening process is considered complete when there are no bubbles on the surface of the product. Then the vibrating table turns off.

The fourth stage is the extraction of the finished fence element from the matrix mold. If all the technological nuances of production are observed, the product easily goes out of shape.

Do-it-yourself installation of concrete fences: work sequence

Hand-made installation of concrete fences is a feasible task if you are not afraid of physical exertion. The technology for installing concrete fences is relatively simple when compared, for example, with the installation of forged fences, where formwork is used.

The first stage is the marking of the territory. A rope is pulled along the perimeter of the future fence, the places where the posts are driven are marked with pegs.

Fixing the pegs in place of future supports

The second stage is the installation of support pillars. You should start with the corner, not the middle pillar. At the installation site of the support, a hole is dug a third of the height of the pillar (when driving, the support will enter the ground for a certain part of its length), the so-called sand and gravel cushion. Next, the support is installed in the ground with mandatory leveling and compaction. The final touch for the installation of the support pillars is the concreting of the hole.

The concrete mixture with which the pillars are poured must be of a very liquid consistency, with a ratio of sand and cement of at least 1: 4.

The third stage is the hanging of the intake sections. The elements of the fence are inserted into the grooves of the supports. If the pillars standing next to each other are set in the ground parallel to each other, hanging will not cause any difficulties, performing in the manner of assembling a Lego constructor. If the fence model assumes the use of two or more sectional elements in height, the sections should be hung "floor by floor" along the perimeter, in order to avoid distortion of the fence.

The vertical joints of the sections are sealed with cement to eliminate gaps, and the gaps between the slabs and the ground are filled with fine gravel.

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Concrete fence manufacturing technology

• Injection method
  • Manufacturing technology
  • Continuation of the workflow

The main purpose of any fence is to fence the territory.

The standard scheme for the construction of a concrete fence.

That is why a concrete fence must have high strength, reliability and, if possible, beauty.

Injection method

Consider the casting method for the manufacture of concrete structures. The concrete mixture prepared in a special mixer has high mobility, non-delamination, excellent casting qualities, and concrete products are quite strong, waterproof and frost-resistant.

In order to make concrete fences, you need:

An approximate diagram of a rectangular in cross-section concrete base for a fence.

1. Special mixer (concrete mixer).
2. Portland cement М500Д0 (without any additives).
3. Sand with a fineness modulus greater than Mcr 2.0 (ideally, the fraction should be 2.5), the content of clay particles in this sand should not be more than 3%.
4. Granite crushed stone more than 800, with a fraction of 0.5-1 cm.
5. Plasticizers.
6. Water.
7. Hand trolley.
8. Vibrating table.
9. Forms.
10. Special graters.
11. Brushes.
12. Trowel.
13. Brush.
14. Pallets.
15. Armature. For posts: 50 cm - B - 1 4 mm, 100 cm - Bp - 1 4 mm, 150 cm - 0.6 cm, 200 cm - 0.8 cm, 250 cm - A3 1 cm, for the frame: steel Bp - 1, with a diameter of 0.4 cm.

Back to the table of contents

The ingredients are loaded into a special mixer in the following sequence: sand - cement - water. To make the poles, you need to wash the gravel in a concrete mixer. After the gravel is clear, the water should be drained. Next, you need to add sand to the gravel, and then cement. All ingredients must be thoroughly mixed (dry) until a homogeneous mass is formed.

Then water is poured into the mixture proportionally. Moisture should be checked visually (squeeze the mixture in your hand). For the stove, the mixture must be made a little thinner than with the oven laying, on the pillars - a little drier. Visually, the mixture for the posts should be a little lumpy.

Diagram for making a concrete pillar with your own hands.

If the mixture begins to "boil" during vibration, it means that this solution contains excessive moisture, which subsequently leads to the "flowing" of concrete products, which is especially scary for the pillars, because during the setting the inner section of the pillar begins to sag.

It is necessary to fill in a special mixer 0.5 parts of crushed stone, a plasticizer solution and approximately 0.5 parts of water. All ingredients should be mixed for 1 minute. After that, the cement is poured, and the mixture is mixed again for 1 minute.

After that, the remaining crushed stone and sand are poured, and the mixture should be mixed again for 3 minutes, gradually adding water to this mixture. Water is added until the concrete mix acquires the required plasticity.

This process will take approximately 5-7 minutes. The total time for mixing the concrete mixture in a concrete mixer is about 10-20 minutes - it all depends on its volume.

A mixture for making a plate can be prepared in a forced mixer, provided that it is unloaded from a height not exceeding 50 cm. The mixture for making pillars is best prepared on a pear, observing the unloading conditions.

The quality of the concrete mix must be determined by eye. High quality mixed mixture has no dry inclusions and does not stratify when vibrated. Also, a properly prepared mixture should easily roll into the so-called "kolobok" with slightly swollen sides, in other words, have the consistency of dough for dumplings.

If the mixer and the vibrating table have spatial separation, then the mixture should be unloaded into manual carts. If there is no space, then the best option there will be a stiffening sheet located under the agitator. From there, the mixture is taken.

Diagram for making a decorative concrete block.

The formation process takes its own beginning from the installation of the form on a special vibrating table. The form must be lubricated by hand using brushes or spraying. If excessive grease has formed, then it just needs to be drained.

In a well-lubricated form, it is necessary to lay and level approximately 40% of the volume of the concrete mixture until a layer of protective reinforcement is formed. Compaction is made by switching on the vibrating table for 20 seconds. After the mixture has been compacted, the welded or bonded fittings should be laid in advance.

Then again you need to turn on the vibrating table. By means of floats, the reinforcement must be deepened into the concrete. After complete immersion of the reinforcement in concrete, the vibrating table is turned off and the surface is rubbed with floats to a perfectly smooth state.

During the manufacture of the posts, during the final filling of the special form, it is necessary to install the upper groove.

Back to the table of contents

The form should be filled 1/3 with concrete and turn on the vibrating table for 30 seconds. Then you need to install a couple of reinforcing bars, add another 1/3 of the mixture and a couple more bars. Then the rest of the mixture is added.

Between these actions, the vibrating table should be turned on for 25 seconds. After the form is completely filled, you need to lay the inner insert, the end of which must be deepened across the form by means of the board and turn on the vibrating table. Next, using a trowel, you need to smooth the surface around the groove, keeping the board at the level of the form itself.

Technological scheme for the production of concrete products.

Then you should turn off the vibrating table and finally smooth out the shape. After the compaction has been completed, it is necessary to rub the open concrete surface with floats. The surface of the resulting product and form must be cleaned of concrete residues using brushes.

De-formwork is carried out by throwing the mold onto wooden pallets. Then slowly you should first raise the 1st side of the form until the product is separated, then you need to, in turn, lifting the edges, remove the form.

Future concrete fences do not need heat treatment. Their hardening occurs due to the heat of the cement hydration. The microclimate required for hardening is created using the pallet structure. Longitudinal ribs and flooring create a volume (closed) in which the material hardens.

Pallets with future concrete fences must be installed in a stack, the height of which is no more than 10 pallets. The topmost piece should be covered with an empty tray in order to create the same hardening conditions. If the outside temperature is less than 5 degrees Celsius, then the stack of pallets must be covered with foil.

Products can be removed after it has gained 50% strength (about a day). They can only be transported in a couple of weeks. Fence panels should be stored vertically and posts horizontally. The color of the fence is carried out only with a facade dye. So, the fence is ready, it remains only to install it.

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Manufacturing and installation of concrete decorative fences

Recently, concrete decorative fences have been widely used for fencing summer cottages and private houses. They gained their popularity due to the decorative structure of the surface of the plates, ease of installation and relatively low price. There are many enterprises and workshops engaged not only in the manufacture of concrete fences, but also in the installation of structures at the customer's site. Such fences do not require the manufacture of strip foundations and can be installed in areas located on steep slopes.

Materials for the manufacture of fence plates

By installing a fence on the site, any owner dreams of its strength and durability. They depend on the quality of the materials used in the construction. There is no doubt that such a structure will be a fence made of natural stone. However, the production time and financial costs are very high. Not everyone can afford to build a hedge. Concrete fences have combined strength, design and price. Most owners of plots and houses would like to do the work on installing the fence with their own hands. This can significantly reduce cash costs. You can mount concrete blocks for the fence yourself, with the help of family members.

The material for the manufacture of slabs is lightweight concrete, which includes water, Portland cement, sand and fine gravel or screenings.

In some cases, plasticizers and coloring pigments are used. To give the fence block strength, it is reinforced with wire mesh. After the product dries, pores often appear on its surface, which affect the ability to absorb moisture. IN winter period this affects the frost resistance of the structure.

In order to avoid the occurrence of such defects, Kevlar concrete was used. Plates made of this material do not have such disadvantages, and the surface is glossy. This construction material is made according to the technology of pellet production for ferrous metallurgy. The technology is simple and consists in enveloping the core, consisting of one or several large particles of granite screening, with a semi-dry mixture of cement and sand. This process takes place in a concrete mixer at high rotation speeds. The preparation time for kevlar concrete is no more than 1 minute.

At the final stage, water is added to the mixture at the rate of about 0.1 l. for 3 kg of the mixture.

The resulting mass is evenly distributed over the shape and vibrated. Due to the small amount of water in the mixture, air bubbles are not formed, due to which defects arise. After the product has dried, painting can be carried out at the request of the customer. It is usually done from the front side. The fence is then ready for installation. For its installation, profile posts are used, into the grooves of which decorative concrete blocks are inserted.

Manufacturing technology

The production of fence panels is based on vibration casting technology. The concrete mix is \u200b\u200bprepared in a concrete mixer with the addition of sand, Portland cement M 400 or 500, crushed stone of fraction 5-10 or screening. The ready-made solution is distributed in metal or plastic forms. Its consistency should ensure free movement of the mass across the matrix. On the vibrating table, the final shrinkage of the mixture is carried out and the entire volume of the mold is filled. The vibration time should ensure that the maximum amount of air is released from the concrete. Finished form goes for drying in a natural way or for steaming in a special chamber. With method 2, the product will be completely ready in a day, and after drying, it will gain full strength in 28 days. Standard sizes the finished fence is 200 x 50 x 4 cm, and the weight is about 70 kg.

Recently, double-sided slabs have begun to be produced for the eurofence. From the standard ones, they differ in the size and location of the texture on both sides of the canvas.

Painting of such products is carried out with ordinary facade paints on both sides in different colors, in harmony with the interior decoration of the courtyard.

Surface staining can be carried out during manufacture by adding dye only to the required areas. This method allows you to reduce the consumption of coloring pigment by half.

These slabs are 200 x 30 x 8 cm and, due to their great thickness, their weight reaches 90 kg. Double-sided fence blocks are installed in special typesetting posts that can support their weight. Such fences have quite good strength characteristics, which allows you to protect the site from the penetration of uninvited guests.

Installing a fence

A decorative concrete fence does not require the involvement of special equipment for installation, and the work is reduced, as a rule, to the installation of pillars, the dimensions of which depend on the number of mounted sections in 1 span. Usually, a fence with a height of 2 m is installed.It does not allow viewing the site from the street side, and for ventilation and giving it lightness, the upper openwork section is mounted. Facade hedges are placed with the textured part outward. To give the inner side an aesthetic appearance, it is painted.

Depending on the relief of the site, the installation of the fence can be done in steps or evenly. This is achieved by selecting supports of different sizes. Cast poles are made in 4 standard sizes for installation from 1 to 4 slabs. The size of the lower part to be concreted is 50 cm - for 1–2 slabs and 75 cm - for 3–4 slabs. The supports have 2 longitudinal grooves with a depth of 4 cm for the installation of plates. In the corners of the site, 2 supports are mounted in 1 pit with the location of the grooves towards the fence line. Poles are painted in conjunction with the entire hedge.

After marking the boundaries of the site, corner supports are installed.

They are leveled, the pits are filled up with stone or pieces of brick and filled with cement mortar. The distance between the centers of the posts should be 2.06 m. With a larger size, the slabs will not hold in the grooves, and with a smaller one, they will not be inserted there. To install the pillars, they dig holes with a shovel or do it with a hand drill. After the installation of all the pillars and the concrete hardening, the fence blocks are installed. This part of the work is carried out by at least 2 people. Each subsequent slab is laid with the lower surface on a pillow of cement mortar... After installation of all sections of 1 span, excess mortar is removed. In the grooves, the fence sheets are wedged, and the remaining slots are filled with mortar.

When installing slabs in type-setting filling supports, the work is carried out in a slightly different way. First, the foundation is made for all the pillars. A reinforcing cage is inserted into it, which must rise above the concrete surface by at least 40 cm. After the mortar has dried, the first section of the support is installed on the foundation surface. These actions are carried out alternately on all columnar bases. Then, double-sided fence plates are installed in the grooves of the sections, after which the support blocks are poured with concrete. Work in this sequence is carried out until the required hedge height is reached. After the installation of the plates is completed, caps are installed on the upper sections of the supports. After that, the entire structure is painted.

Installation errors

The main mistakes when assembling a fence are:

• destruction of slab seats;
• loss of sections from the span.

If the fence posts are incorrectly installed, the canvases are curved into vertical plane and, as a consequence, breaking off the corners of the plates. This situation can be avoided by constantly monitoring the horizontal arrangement of the seats in the grooves of adjacent supports. For this, when installing the supports, it is necessary to check the horizontal position of the elements. In this case, a rail 2 m long and a building level are used. The distance between the posts will be monitored at the same time.

The more accurately the supports are set, the smoother the fence line will be.

The sections fall out due to the large spacing between adjacent supports. The groove in the post has a depth of 4 cm, respectively, the slab must go into it at least 3 cm on each side. Such a defect cannot be eliminated without completely dismantling part of the fence. Usually, all the flaws made during installation appear in the first year after winter. Only carelessness during installation can lead to the appearance of such defects, and, as a result, to additional work and unnecessary expenses.

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. Make reliable decorative fence do it yourself is easiest from type-setting concrete sections.

Decorative concrete fence with stacked posts

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 under a stone, brick, wood or a fence with openwork carved inserts.

Dividing the fence curtain into separate sections facilitates the process of transportation and handling. 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 dacha to inaccessible 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:

1. Concrete fences are expensive compared to those or wood.
2. Another disadvantage is the likelihood of purchasing low-quality products from unscrupulous manufacturers.

A concrete fence will be truly reliable and durable if you use high quality raw materials for its production and take 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.

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).

Production of decorative fences

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

Necessary equipment

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

For the production of concrete sections on a production scale, the most expensive item is the acquisition of molds. A lot of them are required to ensure the variety and the 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.

Prices for fences made of concrete sections

What determines the prices for concrete fences? First of all, from the overall dimensions of the structure, the finishing options chosen by the client, the types of support and foundation, the complexity of installation, the area of \u200b\u200bthe fenced area. If it is important for you to buy a product cheaper, then you can choose a model of modest decorative properties, without complex design elements. It is worth mentioning that concrete fences cannot be too cheap, since the process of creating them is very laborious, like assembly work... In our catalog you can see photos of completed projects, as well as reviews of our clients, which will help you make the right choice.

Decorative concrete fences

The production of decorative concrete fences is especially popular, in the design of which various stylizations are used (under a natural stone of various textures and colors, like a brick, etc.) spectacular decorations - lattice inserts, concrete ornaments, columns and much more. Such an abundance of technical capabilities opens up prospects for the successful implementation of the most complex projects that reflect the aesthetic preferences of our clients.

The advantages of decorative fences include their lower weight, which facilitates the process of transportation and installation. This does not affect the strength characteristics, so that the service life of concrete structures will be more than a dozen years. Here you can find an inexpensive version of the fence in a stylish design.

Decorative concrete fence sections

Production of fences from concrete panels

We offer reliable sectional fences, the production of which is based on the use of modern technologies and high quality materials. Our company carries out the production of concrete products and type-setting panels. Reinforced concrete structures are the most durable and massive, their installation is in demand in industrial areas, on the territory of warehouses and construction sites. The scheme of work used by our company involves the creation of sections of the monolith of the required dimensions, which are then transported to the installation site. For high-quality installation, specialists need to erect a foundation that can withstand the significant weight of the structures.

Decorative concrete fences are less massive, they are erected on site by fastening individual elements between the pillars of the support. We create original typesetting panels, the surface of which imitates natural wood, a rock,

Our company sells reliable structures made of high-quality self-made concrete. The catalog presents a variety of fences, both industrial and decorative - for a house or a cottage. This allows our customers to select the optimal products to meet the practical requirements of the customer. Also, we are always ready to create for you a custom-made design with suitable overall dimensions and appearance. An individual approach allows our customers to be directly involved in the selection of a complete set of each fence, which affects the cost of the finished structure.

You can order an inexpensive or elite fence from us, which will not only protect your home, but also create a harmonious atmosphere, decorate the territory, and complement the architectural ensemble of the building. The prices for the products of our company include measurement, design, delivery, as well as such a service as installation.