A. 50% white or gray cement B52 depending on the desired granite color
B. 50% black or red granite chips
D. Water depending on necessity, temperature
E. Glass water (sodium dioxide)
F. Iron oxides (black, brown incisive, light brown-cream, red, etc.)

VIBRATED PREFABRICATED CONCRETE POURING TECHNOLOGY

A. POURING PREPARATION

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

• Also, check that the ABS mold has a gap in the frame (metal or wood), 1 mm on each side, and that the frame does not compress the ABS mold.

• Check the concrete mixer; it must be clean and free of dried concrete residues.

• Mix 10 liters of water with 1.5 liters of glass water (sodium dioxide) in a bucket, mix well, and then pour into the concrete mixer over the above aggregates.

• For any other concrete color, use iron oxides for that color, dosing from less to more iron oxide in the mixer, to achieve the desired lighter or darker color by weighing the dose of red, black, or gray oxide.

• For red granite, use white cement with red granite chips and red UV-protected iron oxide; the color intensity will depend on the amount of red oxide used.

• For black granite, use black granite chips and black iron oxide; the color intensity will depend on the amount of black UV-protected iron oxide used.

• For the "salt and pepper" granite, use gray cement with black granite chips.

• Mix the above aggregates in the concrete mixer; the concrete must be uniform and well-mixed and ready to pour for 8-10 minutes.

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

• The release agent is very important in vibrating prefabricated concrete pouring. By spraying the molds with release agent, micro-cracks in the polymer molds are prevented. This extends the life of ABS molds up to three times; instead of 200-300 casting-release cycles, using this agent can reach 600-800 cycles.

• Using the release agent eliminates bubbles and impurities on the surface of the poured prefabricated parts. Also, the molds no longer need to be washed after demolding, only wiped and blown dry.

• The ecological mineral release agent is the CHEAPEST product for spraying polymer molds; 1 liter of concentrated release agent is diluted with 25 liters of water, resulting in a cost of ONLY 1.1 RON per liter of ready-to-spray release agent.

• Avoid greasing or spraying ABS molds with diesel, vinegar, oils, etc., as this will create micro-cracks in the molds, which will tarnish in the first stage and crack much faster in the second stage, becoming more brittle. This will result in higher production costs and a lower-quality prefabricated product. 1 liter of diesel > 7 RON, 1 liter of vinegar or various oils > 3-4 RON, while 1 liter of diluted release agent will COST ONLY 1.1 RON.

B. POURING THE CONCRETE

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

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

C. VIBRATION OF THE PREFABRICATE

• Typically, filling the molds with aggregate is done directly on vibrating tables.

• Vibration must be gentle and not last more than 10-15 seconds. This process should be fine, like the hum of bees, until we see air bubbles coming out of the prefabricate.

IMPORTANT
Small batches of prefabricated parts can be poured without a vibrating table.
After filling the mold with the pouring aggregate, shake the filled mold left-right, back-forth, until we see the bubbles exit the aggregate.

D. COVERING WITH FILM

• If we want a high-quality prefabricated part made of concrete, mosaic, plaster, imitation marble, or imitation granite, immediately after vibrating the concrete, place the mold on a flat, straight surface and immediately cover it with a plastic sheet (nylon) of any kind.

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

• Pouring aggregates of any kind at temperatures below +10°C is prohibited.

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

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

• Usually, prefabricate drying areas are specially designed and checked to ensure a high-quality finished product.