Polymer-sand curbs represent a novel approach for contemporary construction and landscaping endeavors. Blending the strength of polymers with the organic beauty of sand, these curbs provide a sturdy and fashionable solution for demarcating borders in outdoor areas such as gardens and walkways.
These curbs are available in a variety of styles, each tailored to suit unique requirements and tastes. Polymer-sand curbs come in a variety of shapes and sizes, and they can even be made to order. They blend in perfectly with any project. They are appropriate for commercial properties, public parks, and residential gardens due to their versatility.
Although installing polymer-sand curbs is a simple procedure, stability and longevity need careful execution. The installation process requires careful ground preparation, precise placement, and secure fixing. Professional results are achievable even for a do-it-yourself enthusiast with the correct tools and techniques.
The weather resistance of polymer-sand curbs is one of their primary benefits. Their resistance to cracking and deterioration sets them apart from traditional materials, rendering them a durable and low-maintenance option. Their environmentally friendly composition and resilience make them a great choice for sustainable building methods.
Polymer-sand curbs combine the strength of polymers with the innate resilience of sand to provide an eco-friendly and long-lasting substitute for conventional concrete curbs. They are available in different varieties to meet diverse landscaping and construction requirements, ranging from robust road edges to garden pathways. It is easy to install, just needs a few basic tools and supplies, and is a quick and effective way to improve outdoor areas. The main characteristics, advantages, and easy installation instructions for polymer-sand curbs are covered in this article, making it simple for both experts and do-it-yourselfers to enhance their projects.
- What are polymer-sand curbs?
- Characteristics
- What is the difference between polymer and others?
- Regulatory documents
- Varieties
- By type of material used
- Purposes of application
- Production method
- By shape
- Materials for creation
- Production technologies
- Is it possible to do it yourself?
- Installation rules
- Pros and cons of use
- Average prices for products and their installation
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What are polymer-sand curbs?
This term, also known as a polymer-sand curb or sand polymer curb, has only recently been used in technical literature. In any event, this is a building product that is used to create or repair pavement and road surfaces. Its raw material is a composite material that has sand filler added to it.
Composites are a kind of plastic that vary in properties based on the makeup of the additives combined with the working hot mass. After that, hot pressing is used to create the goods. The curb structure becomes extremely strong after such sintering because of its low porosity.
Applications for curb stones made of polymer sand:
- improvement of private and multi-storey buildings;
- sidewalks near children"s and sports grounds, garden paths and landscape design;
- road surface at car washes;
- trade and exhibition areas;
- building blind areas;
- parks and recreation areas.
The sand polymer curb’s complete spark safety enables you to use it to protect the areas around gas stations, oil production facilities, and other establishments with a high risk of fire.
Characteristics
Because of the forms’ maximum dimensions and the pressing equipment’s capabilities, PPB are only produced in lengths of 500 mm. They can vary in size in cross-section; on average, they measure 200 by 50 mm and weigh 4 kg.
Large manufacturers voluntarily certify this product even though it is not required by law in the Russian Federation, which makes border modifications like this more competitive.
The structure of the filling mixture, the degree of equipment on the industrial line, and the appropriate quality of the raw materials utilized all affect the technical properties of polymer sand borders.
Key features of polymer sand borders include:
- Environmental safety, do not emit odor and carcinogens when heated, this is due to the fact that the working composition includes 75% sand and 25% environmentally friendly food plastic and heat-resistant dye. Heating of the working mass occurs at T=250C.
- Water-repellent characteristics, increases frost resistance of PPB up to F500 from -65 to +160 C.
- Water absorption no more than 0.03%, which is ensured by the technology of "sintering" particles.
- PPB density 1600-1800 kg / m 3 .
- Abrasion of the material – 0.05-0.1 g / cm 2 .
- Compressive and bending strength – 17-25 MPa;
- Temperature resistance from -70 ° C to + 250 ° C;
- High resistance to UV rays and aggressive environments: acid and alkali.
- Impact resistance 250 kg/cm2, such strength cannot be broken even with a sledgehammer.
- Thermal conductivity – 2700 J/m2 sec.
- High warranty obligations 20 years.
- High service life of more than 50 years.
What is the difference between polymer and others?
Polymer sand curbs are construction materials made with cutting-edge technologies for sidewalk and road systems to enhance densely populated areas. The designers made an effort to reduce the drawbacks of the granite, metal, rubber, and cement counterparts.
Polymer-sand curbs differ from other kinds of curb stones used in road construction in the following ways:
- Rubber curbs (RB): TTR surpass them in temperature difference from -65 to +160 C against from – 45 to +60 C for RB; in density 1800 kg/m3 against 850 kg/m3 for RB; in frost resistance 500 cycles against 20 for RB; in service life 50 years against 10 years for RB; by price advantage for RB – 870 rubles./m.p.
- Steel curbs (SB). They have advantages over PPB: high length up to 2 m, which speeds up the installation process, specific weight per unit length and lower price for a curb 200 mm high and 2000 mm long – 670 rubles./m.p. PPB exceed steel curbs in anti-corrosion characteristics and resistance to aggressive environments, as well as in service life 50 years versus 10 years for SB.
- Concrete road curbs obtained by vibration pressing (BVB): PPB have greater chemical resistance against BVB; higher frost resistance F500 against F200; long service life of 50 years against 20 years for BVB; low weight 4 kg against 18 kg for BVB.
- Granite curbs have more preferable characteristics than PPB in all respects except price and weight: density of 2700 kg/m3, melting point of 1260 C and service life of over 50 years.
Regulatory documents
As per the extant regulations in Russia concerning certification, manufacturers are free to choose to voluntarily certify this kind of product rather than having to comply with mandatory requirements.
However, this kind of product must adhere to the technical guidelines created for polymer sand products as well as the Unified Sanitary, Epidemiological and Hygienic Requirements No. 299-2010, which are in effect throughout the Customs Union.
The following indicators are looked for in finished products in order to verify PPB quality certificates:
- organoleptic indicators for odor intensity;
- release of prohibited substances into the environment;
- radiological indicators;
- quality of raw materials;
- strength;
- frost resistance;
- dyes, uniformity and color fastness.
White stains result from a temperature regime violation, while foreign inclusions on the polymer-sand border surface suggest the use of inferior raw materials. Since they cannot ensure strength and durability, such curbs cannot be installed.
Varieties
Curbs made of polymer are intended for urban landscaping. PPB comes in a wide range of varieties:
- for parks and pedestrian areas;
- adjoining areas;
- for installation in general purpose areas.
PPB are categorized by type of source material, area and purpose of application, production method, and released form so that customers can easily navigate all modifications of such products.
By type of material used
PPB has a roughly similar basic composition; specifics are provided when the product’s technological documentation is being developed. However, the kind of material used might change. Thus, polyethylene with both high and low pressures, or a combination of both, can be utilized as a binder.
Production waste and food plastic consumption are the usual sources of material for the polymer binder. The use of inferior crushed plastic and granules depends on the number of workers on the production line. This option is much more affordable, which makes it the preferred choice for many PPB manufacturers.
Aluminum foil and machine oils are the most undesirable materials that can become secondary raw materials in the PPB production process. They can totally destroy the material’s internal structure when used in large quantities.
Purposes of application
The uses for polymer sand curb stones vary. They are well-represented in both the road infrastructure and the city and other settlement improvement systems. Regarding this, they are separated into:
- road;
- street;
- garden;
- park.
Installing them in parks, recreation areas, garden plots, and inter-quarter driveways is more desirable.
The most common shape in this situation is a standard rectangular one that is 500 mm long, varied in thickness, and has a small rounding on one side. The intended shape of the road surface fence and sidewalk is formed by installing them fairly closely to one another while accounting for thermal expansion.
Production method
The fundamental setup of the machinery used to produce polymer sand curbstones varies depending on whether the production process is carried out entirely by automated lines or partially by hand. For instance, raw material loading into the APN hopper and pressing machine is done by hand when utilizing a construction mixer in a process line.
Additionally, there are two ways to process raw materials made of recycled polyethylene:
- The substance after the agglomerator is mixed with solid crushed sand and additives for subsequent feeding to the APN bin.
- In the extruder, ball polymers are crushed, mixed with sand and rigid polymer with pigmentation and feeding to the APN bin.
- Basic version of the equipment for polymer-sand products:
- Mixer with automatic feed of raw materials – bins and belt conveyors or a construction mixer.
- Melting and heating unit with a screw for feeding raw materials and a working chamber for a 3-stage sintering process: preheating with moisture removal, melting and degassing.
- Vertical press with a force of 63 to 400 tons and a work table.
- Agglomerator of polymer raw materials for crushing film waste with a capacity of up to 200 kg / h.
- Molds – according to factory developments in the shape and type of PPB.
By shape
The most common shape for road surfaces and walkways is a standard rectangular with a small rounding on the front side. The power of the press and the standard forms that are available set limits on the sizes of individual elements.
Street and road polymer sand curb sizes most frequently found are:
- 500X200X50 mm, 5 kg;
- 500X200X30 mm, 3 kg;
- 500x250x55 mm, 6.8 kg;
- 500x150x55 mm, 4.1 kg.
Decorative borders are typically placed on garden plots and in recreational areas, where they are not subjected to heavy loads but are nonetheless required to adhere to specific design specifications.
Various forms are created by businesses based on the preferences of their clients. They can mimic various building materials and be prefabricated.
Common designs for polymer sand borders:
- "Country" for mosaic tiles.
- "Labyrinth" for tiles under natural stone.
- “Brick” to look like a red standard brick.
- “Old stone”, which goes well with paving stones and is in harmony with the “Alpine slide”.
Materials for creation
The products are referred to as polymer sand because, based on the proportional ratio, sand makes up the majority of the loading mass. The basic ingredients that go into making polymer sand borders are as follows:
- 23 – 38% polymer binder.
- 60 – 75% filler in the form of pure sand with a fraction of up to 3 mm. It must be dry, since high humidity during the production of PPB leads to the formation of voids in its structure. Granite screenings, broken ceramic bricks, glass, porcelain, basalt and quartzite can also be used as a filler.
- 2% pigments and plasticizers. The first ones provide through coloring, for this purpose red lead, chromium oxide, cobalt and titanium dioxide are used. The second additives increase the mobility of the mixture and facilitate the process of forming the working solution, for this purpose dibutyl phthalate and tricresyl phosphate are used.
- For reinforcement, additional synthetic and organic and mineral fibers, such as asbestos, acetate and cotton floss, can be added, thereby increasing the tensile and bending strength of the resulting material.
Sand has the highest volume within the PPB working mass, so its quality and maximum dimensions are required. It needs to be sifted and pre-washed as well.
After that, it is put in a special oven and heated to a high temperature for calcination. The polymer sand borders will only be uniformly composed, free of air bubbles and inclusions, in this scenario enabling the products to last the full manufacturing period.
Sand can be any, both river and quarry, but it must be without clay and dust inclusions and with a fraction of no more than 3 mm.
This curbstone modification uses a well-known polymer as its primary binding material; this polymer is used to make dishes, furniture, and other household items.
Although cold polymer is in a solid state, it is safe and chemically inert. There are only two conditions in which it can undergo a chemical reaction and change its aggregation state: solvents or temperatures exceeding 220 C.
Liquid polymers possess all the necessary properties to produce polymer-sand products, including high activity, good adhesion, vulcanization, and mixing ability.
Recycled polymer requirements:
- Density 0.92-1.14 g/cm 3 .
- Melting point, 120°C.
- Frost resistance, -70 °C.
- Bending brittleness temperature, from -60 to +150 C.
- Hardness, 14-25 MPa.
- Humidity, no more than 5%.
- Pollution, no more than 2%
- Presence of paper, no more than 2%
- Presence of glass no more than 15% with inclusions no more than 2 mm.
Production technologies
To achieve superior PPB products through production, you will require the purchase of sophisticated automated equipment, which is highly costly in today’s market.
Such production is labor-intensive and necessitates the organization of step-by-step production control over the quality of polymer components, as well as strict adherence to process regulations. We can only ensure that polymer sand borders will match the specified specifications in this situation.
Technology used in PPB production:
- Polymer product waste is sent to a site where it goes through the processes of crushing, sorting and removing paper and metal. Soft and hard plastic are crushed separately into fractions of 1-15 mm according to the first option and 1-25 mm according to the second. For the production of polymer sand borders, it is recommended to mix together: 60% of “soft” and 40% of “hard” polymer.
- Crushing in drum-type installations of polymers occurs using knives, while the fraction can be obtained heterogeneous, which does not worsen the characteristics of the finished PPB. Nevertheless, a smaller fraction creates a smoother and more attractive shape of the finished product.
- The agglomerator is used in waste processing, can also be used as a high-speed mixer and dryer, and built-in knives allow you to get a more uniform composition of the working mass.
- Then the crushed mass enters the melting and heating unit (MHU) through a loading hopper, usually 80-90 kg. In it, the thermoelements heat the composition to 250 C and mix it evenly until it becomes homogeneous, plastic and able to spread, but not be very liquid.
- The MHU valve is opened, the extruded mass is cut off with a knife, weighed and placed in a mold. After part of the mass has been taken for the manufacture of the curb, an equivalent amount of a new portion of the mixture is added to the MHU through the hopper.
- The heated mixture from the MHU is fed into the mold, which is closed for 2-4 minutes depending on its size.
- A matrix with a cooling system and ejectors is installed on the lower plate of the work table. Moreover, the temperature conditions of the matrix and punch are different, which is ensured by 2 independent cooling circuits or due to different diameters of the cooling pipes. With such temperature heating, a glossy surface of the product is obtained, if the same temperature conditions are created on both sides, the product will be matte.
The following supplies are needed to produce 3600 kg of polymer sand curbs:
- sand, 3030 kg;
- secondary plastic, 540 kg;
- dye and plasticizers, 30 kg.
If no dye is added, the product will press into a gray color that resembles concrete curbs and will be less expensive than colored PPB. Raising the temperature above the specified limits is prohibited while the PPB technological process is being implemented. Considering that the polymer structure will be harmed as a result.
Is it possible to do it yourself?
In theory, you could make these items by hand, but to do so, you would need to buy the required tools and put them together into a single technological line. The home needs to have a strong electrical supply and 100 m 2 of free space for this.
Such circumstances are not common among home craftsmen, and without them, it will be hard to get quality certifications for the goods. Selling non-certified goods in the current market is also a major challenge.
It is safe to conclude that production conditions are the only way to ensure the quality of polymer-sand curbs. The fact that there are currently no affordable equivalents of this type of production should also be considered, as this has a major impact on the final cost of PPB and makes it impossible to lower their cost by using inferior components.
Installation rules
A well-prepared base is regarded as the prerequisite for the installation of polymer-sand curbs in an excellent manner. While a gravel-sand cushion is ideal for this, a concrete base must be made for road conditions.
Laying sand curbs with polymer technology:
- Prepare a road construction site plan, measure it and draw the outline of the future road surface with exact dimensions on paper. Based on this plan, calculate the necessary materials for the polymer sand curbs, sand, cement and crushed stone.
- Using pegs and a rope, break up the site according to the previously completed plan and separately mark out the places for the trenches for the polymer sand curbs.
- Take out the turf and soil from the trench taking into account the height of the product so that after laying the foundation, the product comes out to the required height.
- Compact the soil under the base of the polymer sand curbs.
- Pour 50 mm of a mixture of crushed stone and sand, moisten and compact.
- Make markings for the location of the polymer sand curbs, drive in pegs and pull the cord.
- Install the polymer sand curbs taking into account the expansion joint.
The curb line’s geometry is upset when a lot of plastic is used to fill it; while the curb looks gorgeous and glossy, high temperatures cause the plastic’s contours to bend. Without expansion joints, curbs will flex and create surface hills; 3 mm is thought to be the minimum gap for these kinds of products.
Pros and cons of use
Due to their many benefits, polymer-sand curbs are highly preferred by both large industrial clients and individual consumers.
For buyers and experts, the following are the primary benefits of Polymer Sand Borders:
- High technology of laying works, which allows them to be installed manually, in a short time.
- Ease of use, they do not require special care and maintenance throughout the entire service life.
- High maintainability, any damaged area can easily be replaced with a new.
- High shockproof and vandal-proof characteristics, which are provided by the elastic and binding material. For comparison, 20 mm PPB can withstand the same load as 40 mm paving stones. Such PPB does not break when dropped during transportation.
- High ability to stain, higher than that of concrete and fourth stones, color resistance remains throughout the entire period of the polymer -sand border service.
- Long warranty period without destruction, declared by the manufacturer of at least 20 years.
- High anti-acid, anti-alkaline and anti-corrosion characteristics, with low abrasion and spark extinguishing, the material does not burn in a fire, but can char.
- Easy to process and cut, if necessary, to manufacture additional elements.
- Low abrasion 0.016 g / cm 2 versus 0.7 g / cm 2 as required by GOST for road surfaces.
- Low weight, more than 3 times lighter than concrete, reinforced concrete and granite products, which simplifies installation and reduces transportation costs for the delivery of the material.
The following drawbacks of this curbstone modification are attributed by users:
- High longitudinal expansion at high temperatures up to 2 mm, which must be taken into account when laying PPB.
- Low adhesion, so in order for them to stick to the cement mortar, special internal grooves are arranged in the body of the PPB.
- Afraid of piercing and sharp objects.
- Limited sizes, since larger forms will require powerful steel molds, which are very expensive and not every enterprise is ready to buy them.
- High price in relation to concrete curbs obtained by vibration pressing, due to high specific electricity standards for the production process.
Average prices for products and their installation
The cost of labor, large equipment, substantial energy consumption, and the size of the polymer sand curbs currently determine their price. However, since secondary raw materials are used by the majority of these industries, raw materials have less of an impact on price.
PPB measuring 500 mm in length, 150 to 250 mm in height, and 30 to 60 mm in thickness are sold through the retail network. Its purchase price, calculated at one milligram, is ten to fifteen percent more.
Average prices On colored polymer -sand borders:
- 500x150x50 mm, weight – 3.78kg, 166 rubles./PC.
- 500x200x30 mm, weight – 3 kg, 132 rubles./PC.
- 500x200x50 mm, weight – 5 kg, 220 rub./PC.
- 500x200x55 mm, weight – 5.5 kg, 250 rubles./PC.
- 500x250x30 mm, weight – 3 kg, 132 rubles./PC.
- 500x250x50 mm, weight – 3.75kg, 165 rubles./PC.
The length of the road surface, the curbs’ modifications, the garden surface’s or road’s intended use, and the technology used to lay the base beneath the product all affect how polymer-sand curbs are laid.
It is up to 250 rubles per month on average for roads with high traffic volume and concrete bases; this is 25–30% less expensive than installing a vibrocompressed curb. This results from lower labor intensity, lower transportation costs, and a single product that weighs less.
Because more products must be made, installing polymer-sand curbs of elements on combined sections with alternating straight and curved sections will cost 10% more.
Feature | Description |
Types of Polymer-Sand Curbs | These curbs come in various shapes and sizes, designed to suit different landscaping and construction needs. Common types include straight, curved, and corner pieces. |
Material Composition | Polymer-sand curbs are made from a blend of sand and polymers, making them durable, lightweight, and resistant to weather conditions. |
Advantages | They are easy to install, environmentally friendly, and require minimal maintenance. Additionally, they are resistant to cracking, chipping, and erosion. |
Installation Technology | The installation involves preparing the ground, placing the curbs in the desired layout, and securing them with stakes or adhesive. Proper leveling and alignment are crucial for a neat finish. |
For edging and defining spaces in landscaping and construction, polymer-sand curbs provide a cutting-edge and long-lasting option. They create a product that is resilient to impact, weathering, and corrosion by fusing the strength of polymers with the adaptability of sand. These curbs are available in a variety of styles, each intended to fulfill a particular purpose, such as parking lot dividers, garden borders, and pathways.
Polymer-sand curb installation is a simple task that can be completed by professionals or do-it-yourselfers. The process of installation entails preparing the ground, building a strong foundation, and then firmly placing the curbs. For the curbs to be stable and long-lasting, proper alignment and spacing are essential. The installation can be finished quickly and neatly with the correct equipment and supplies, giving a long-lasting finish.
In general, polymer-sand curbs are a great investment for any project involving building or landscaping. They provide long-term durability, aesthetic appeal, and practical advantages. These curbs are a flexible and dependable option whether you want to improve the appearance of your garden, increase the security of walkways, or define boundaries in parking areas. You can maximize the benefits of this cutting-edge product by being aware of their varieties and installation methods.