In order to lay out a track or a whole plot in the country, for example, from paving stones, it is not always necessary to buy material. Today, a high level of development of technology and science, as well as a fairly simple technology for the production of paving slabs, allow you to create paving stones on your own. Moreover, the quality of home tiles rarely differs from the factory, provided that all production rules have been observed.
Consideration of production methods
It is worth saying right away that there are two different technologies for the production of paving slabs. The first method is called vibrocasting, the second - vibropressing. It is worth adding here that vibrocompression is available only in the factory, since this process is more complicated in execution. But with the help of vibrocasting it is quite possible to engage in the independent production of paving stones. Another important part of paving slab manufacturing technology is the use of regular shapes.
Types of molds for the production of material
If you purchase ready-made forms, then they can be of the following varieties:
- From polyurethane. Such molds can withstand up to 100 casting processes. That is, in one form you can make 100 tiles.
- There are forms of plastic. They withstand up to 250 casting processes.
- The most durable are considered forms of plastic rubber. One form can be used more than 500 times.
Naturally, the price will increase along with the number of cycles that the form withstands. Therefore, rubber and plastic are most often used in production, and polyurethane molds are quite enough for independent production. In addition, if handled with care, it is possible to manufacture a little more than stated.
In addition, home craftsmen have developed technology for the manufacture of paving slabs from plastic bottles used as molds. If we talk about purchased options, then about 5-6 polyurethane samples will be enough to make more than 500 tiles.
Applying Templates
In addition to the manufacture of the material in the molds, a method called “in place” is also used. For this, form templates are used. The manufacturing technology of paving slabs in this way is quite simple, but its quality suffers. Therefore, it is best to use the method if you need to equip an auxiliary track leading, for example, to the barn.
In order to produce raw materials in this way, you need to prepare an even base. Templates are placed on it, into which the concrete mixture is poured. So it costs a couple of hours. Then the form is removed and the finished tile remains in place.
It is important to note that if the quality of the tile practically does not play a role, then you can also make such mold templates with your own hands. In this case, you will not have to spend money, only for the purchase of material for mixing the solution. Home-made manufacturing is also more profitable in that you can give any shape to the future tile.
Mold making
The manufacturing technology of paving slabs, the recipe for which is almost the same, begins with the manufacture of forms. Of course, you can buy them, but in order not to splurge, it is better to do everything with your own hands.
The simplest and most universal option for a tile is a square with a side of 30 cm. This is due to the fact that sufficient strength is provided if there is pressure on the bending of the tile, and it is also quite convenient to cut it.
In order to make a suitable shape, you need to take the right amount of wooden bars with a cross section of 60x30 mm. With their help, the shape of the square is laid out, the inner side of which is 30 cm, and the depth is 60 mm. It is best to fix the frame with self-tapping screws. It is easiest to twist them when you need to remove the product.
The technology of making paving slabs with their own hands in home-made forms completely admits the presence of any pattern. As a basis, it is best to use an elastic piece, for example, an old rubber mat with a suitable pattern. The mat is laid, and a form is placed on top of it. Thus, the output will be a tile with a relief. To speed up the process, it is recommended that you have at least 10 forms in stock.
Tile casting methods
The technology for manufacturing paving slabs by vibrocasting is divided into two methods. It is possible to produce paving stones with a single-layer or two-layer method. The method itself involves pouring a solution into a mold, followed by compaction of the composition using a vibration process.
The single-layer manufacturing process is quite simple. The mold is poured with a solution, placed on a vibrating table, undergoes a compaction procedure, after which the mixture is infused and solidifies in a mold for two days. After that, you can deal with the formwork, that is, removing the finished tile from the mold. However, the aesthetics of such a tile is lower than that of a two-layer one, and therefore it is used in those places where the appearance does not play a big role.
The technology of manufacturing paving slabs at home using the two-layer method is a more complex process. The two-layer pouring process is as follows: a layer of a solution mixed with a coloring pigment is poured. The layer thickness is 1-2 cm. At this time, the form should already be installed on a working vibrating table. Immediately after this, without waiting for the mixture to solidify, the main layer is poured. Here, the addition of dye is no longer required.
After that, the form is kept on a vibrating table for 15-30 seconds. After two days, you can remove the tiles from the molds and fold them for final drying in a dry and cool place. It is very important if the tile has more than one layer, then it must be covered with a plastic film for the period of solidification of the solution. This is done in order to avoid premature evaporation of moisture and cracking of the product.
Front layer
The technology of manufacturing paving slabs, at home or factory, involves the formation of the front layer. It has increased strength as well as aesthetics. This shell has a color, depending on the chosen dye, as well as a glossy surface.
Here it is recommended to use not gray cement of the M500 brand, but white of the same brand. This will lead to the fact that the top layer will be more saturated, and also will not have a gray tint.
As materials for this layer are used:
- white cement M500;
- crushed stone 5-10 mm;
- water;
- color;
- dispersant;
- sifted sand.
Cobblestone Recipe
The easiest way to explain the technology of paving slabs is by giving a specific example. For larger scale preparation, it is best to use a concrete mixer.
10 liters of water are poured into the device. If you want to make a colored tile, then add the desired dye to it. Next, 750 ml of an aqueous dispersant solution is added. When everything is in place, you can turn on the concrete mixer.
3 buckets of ShchPS and cement of the M500 brand fall asleep into the already working equipment. In this composition, you need to leave the car to work for one minute. After that, you need to add three more buckets of dropout to the composition.
After this, the concrete mixer is left for 15-20 minutes. During this time, the solution should acquire a uniform consistency. When the result is achieved, the mixture is poured from the device into the tub where the product is molded. It is important to note that this is exactly the face layer for a large number of tiles.
Tile base
The most significant difference in the mixture between the main and the front layer is that a plasticizer will be used instead of the dispersant. The main proportion is one part of cement and three parts of sand. The amount of plasticizer added is equal to the amount of dispersant in the face layer.
It is best to consider a more specific example on large volumes. A concrete mixer is also used here.
First, pour 12 liters of water, then 750 ml of an aqueous plasticizer solution. Next, the concrete mixer is turned on and 5 buckets of ShPS and 3 buckets of cement are added. When these substances are added, it is worth adding 3-4 more buckets of dropout. It is very important to note here that the base layer does not need to add dye. The mixture is also mixed for about 15 minutes, until a homogeneous mass is obtained and poured into a tub.
In order to have enough to lay 1 square meter of pavers with the thickness of the material, you will need the following amount of feedstock:
- 90 kg of a mixture of crushed stone and sand;
- 25 kg of cement grade M500;
- 100 grams of dispersant and 120 grams of plasticizer;
- dye in the amount of 600-800 grams.
Performance improvement
It often happens that you need to significantly increase the strength of the tile so that it can withstand the weight of, say, a vehicle.
Most often, to improve strength, an operation such as reinforcement is performed. As a reinforcing substance, it is best to use "notch". By this is meant expanded steel. It is cut to the desired size, having a shape. For these purposes, steel having a thickness of 1-2 mm is suitable. Lay the reinforcement layer on top of the front.
Then it is covered with concrete so that the solution layer has one level with the edges of the form. In addition to steel, at home, it is completely allowed to use cross-wired wire or reinforcement.
Tile extraction
If twisted wooden blocks were used as a form, then one of the edges is unscrewed so that the frame can be moved apart. The finished paving stones are removed, and the mold is assembled back. It is important to note that the tile must be infused for 10 days in a cool place to gain the necessary strength.
If you used a purchased form of polyurethane, then you need to prepare a bath with hot water in advance - +60 degrees Celsius. The tile form is placed in water, the polymer softens in a couple of minutes, and the paving stones can be removed. She will also need to be insisted for 10 days.
For example, if 10 forms are available, then the work is structured this way. Every day, 5 products are extracted, and the next 5 blanks are made. The next day also with the following 5 forms. It is worth adding that there is a separate technology for manufacturing luminous paving slabs.