A. 50% White Cement B52

B. 30% White Marble Powder or White Sand

C. 20% White Marble Mosaic, Granulation 6-8 mm

D. Water according to need, temperature

E. Glass Water (Sodium Silicate)

F. Titanium Dioxide (White)

G. Iron Oxides (Black, Dark Brown, Light Brown-Cream, Red, etc.)

VIBRATED PREFABRICATED CONCRETE CASTING TECHNOLOGY

A. CASTING PREPARATION

• Check the ABS mold in which the aggregate will be cast, it must be clean and free of impurities inside.

• Also, ensure the ABS mold has a 1 mm play in the frame (metal or wood), making sure the frame does not clamp the ABS mold.

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

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

• For excellent white color, we recommend using 150 grams of titanium dioxide or white iron oxide for a working concrete mixer.

• For any other color of concrete, use the corresponding iron oxide, adjusting the dosage from less to more iron oxide in the concrete mixer, to achieve the desired lighter or darker color by weighing the oxide dose.

• Prepare and mix the above aggregates in the concrete mixer; the concrete (aggregate) must be uniform and well-mixed, ready for pouring.

• Spray the ABS mold with ecological mineral decoform before pouring the well-mixed aggregate from the concrete mixer.

• Decoform is very important in casting vibrated prefabricates. By spraying the molds with decoform, microcracks in polymer molds are avoided. This extends the life of ABS molds up to three times, from 200-300 casting cycles to 600-800 cycles.

• Using decoform eliminates air bubbles and impurities on the surface of cast prefabricates. Also, the molds no longer need washing after de-molding but only wiping and blowing off.

• Eco-friendly mineral decoform is the CHEAPEST product for spraying polymer molds. One liter of concentrated mineral decoform diluted with 25 liters of water results in a cost of ONLY 1.1 RON per liter of ready-to-spray decoform.

• Avoid greasing or spraying ABS molds with diesel, vinegar, various oils, etc., as this will create microcracks in the molds, which will dull in the first phase and crack much faster in the second phase, becoming more brittle, leading to higher production costs and lower-quality prefabricates. Diesel 1 liter > 7 RON, vinegar or various oils > 3-4 RON, while 1 liter of diluted decoform will COST ONLY 1.1 RON.

• After spraying the ABS mold with decoform, take a handful of iron oxide (black, red, green, blue, brown, etc.) and scatter it randomly at the bottom of the mold, leaving streaks. These streaks will form the veins in the imitation marble.

• Use gloves and protective goggles when applying iron oxide to molds.

• After randomly scattering iron oxide in the ABS mold, use a scoop to add a 2-4 cm thick layer of aggregate in the mold, then pour the remaining aggregate until the mold is full.

B. CONCRETE CASTING

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

• We recommend using 4mm welded mesh for flat prefabricates and ribbed steel rods for columns and long or very long elements.

C. VIBRATION OF PREFABRICATES

• Typically, the molds are filled with aggregate directly on vibrating tables.

• Vibration should be gentle and last no more than 10-15 seconds. This procedure should sound like a soft bee buzz until air bubbles start rising from the prefabricate.

IMPORTANT
Prefabricates can also be cast in small batches without a vibrating table.
After filling the mold with the casting aggregate, shake the filled mold left-right, forward-backward until you see the air bubbles rise from the aggregate.

D. COVERING WITH FOIL

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

• The ABS mold with the covered aggregate must rest for 24 hours for curing.

• Casting aggregates of any kind below +10 degrees Celsius is prohibited.

• After 24 hours, de-mold the prefabricate by turning the mold onto a table and shaking gently until the prefabricate comes out of the ABS mold.

• The flatness of the drying area is vital as it will help you or your clients achieve easy and high-quality assembly.

• Drying areas for prefabricates of any kind are usually 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!