A. 50% white cement B52
B. 30% white marble dust or white sand
C. 20% minimum granulation powder from marble dust
D. water as needed, depending on temperature
E. glass water (sodium silicate)
F. white titanium dioxide
G. iron oxides (black, dark brown, light brown-cream, red, etc.)

TECHNOLOGY FOR CASTING VIBRATED PREFABRICATES

A. PREPARATION OF CASTING

• Check the ABS mold in which the aggregate will be poured; it must be clean and free from impurities inside.

• Also, check that the ABS mold fits with a 1 mm clearance on each side in the frame (metal or wood), and the frame should not press the ABS mold.

• Verify the concrete mixer; it must be clean and free from dry concrete residues or impurities.

• This recipe can also be mixed in a bucket using a drill with a mixing attachment.

• Mix 10 liters of water with 1 liter of glass water (sodium silicate) in a bucket, then pour it into the concrete mixer with the aggregates mentioned above.

• To achieve excellent white color, it is recommended to use 150 grams of titanium dioxide or white iron oxide for each concrete mixer batch.

• For any other concrete color, use iron oxides in the desired color, adjusting the dosage from less to more oxide depending on the desired shade by weighing the oxide dose.

• Prepare and mix the aggregates in the concrete mixer until the concrete is uniform and ready for pouring.

• Spray the ABS mold with ecological mineral release agent before pouring the well-mixed aggregate.

• The release agent is crucial in vibrating prefabricate casting. By spraying with the release agent, microcracks in polymer molds are prevented, extending the life of ABS molds up to three times, from 200-300 casting cycles to 600-800 cycles.

• Using the release agent eliminates bubbles and impurities on the surface of the cast prefabricates. The molds no longer need to be washed after de-molding but just wiped and blown dry.

• The ecological mineral release agent is the CHEAPEST product for spraying polymer molds, with 1 liter of concentrated release agent diluted with 25 liters of water, costing ONLY 1.1 RON per liter for spraying.

B. CASTING THE CONCRETE

This recipe involves making two mixtures:

1. One part of 1 kg white cement is mixed with 1 kg of white marble dust.

2. 3 liters of water are mixed with 1 liter of glass water and poured into a bucket, along with 1 kg of white cement and 1 kg of marble dust, mixing well.

• Pour the resulting mixture into the ABS mold, filling about one-third of the mold.

• The second mixture consists of 50% white cement and 50% marble dust, with 1 liter of glass water and 10 liters of water. Mix well and pour the second layer into the ABS mold until full.

• Ensure that there is no break in pouring of more than 5-8 minutes.

• Pour the concrete into the ABS mold up to half of its height in the first phase, then reinforce with welded mesh or steel rods both lengthwise and widthwise. After reinforcing, pour the remaining concrete into the mold.

• It is recommended to use 4mm welded mesh for flat prefabricates and ribbed steel rods for poles and long elements.

C. VIBRATION OF THE PREFABRICATE

• Typically, the mold is filled directly onto vibrating tables.

• Vibration should be smooth and last no longer than 10-15 seconds. The process should be as gentle as the buzzing of bees until bubbles rise from the prefabricate.

IMPORTANT

• Prefabricates can also be cast in small series without a vibrating table.

• After filling the mold with the casting aggregate, shake the filled mold left-right, forward-backward until bubbles appear from the aggregate.

D. COVERING WITH FILM

• If you want to produce high-quality concrete, mosaic, plaster, marble imitation, or granite imitation prefabricates, immediately after vibrating the concrete, place the mold on a flat surface and cover it with any kind of film (nylon).

• Leave the ABS mold with the covered aggregate for 24 hours to harden.

• Casting is prohibited at temperatures below +10°C.

• After 24 hours, remove the mold by flipping it over onto a table and gently shake until the prefabricate comes out.

• The flatness of the drying place for the prefabricate is critical, which will help you or your clients with easy and quality assembly.

• Typically, the drying areas for prefabricates are specially arranged and checked to ensure a high-quality finished product.

FOR MORE DETAILS, CALL 0742208730

We wish you success in obtaining high-quality prefabricates!