All the intricacies of the production of road curbs

Although they may appear to be straightforward constructions, road curbs must go through a rigorous manufacturing process to guarantee their robustness and usefulness. Every step of the process, from material selection to final touches, is vital to producing a product that can endure traffic and time.

Choosing the appropriate kind of concrete is the first step in the process. This isn’t just any mix—it needs to be specially made to withstand the challenging circumstances found on roads. The concrete mix needs to be robust, long-lasting, and able to withstand impacts, heavy loads, and extreme weather.

The next step is to mold the curbs after the ideal mixture is prepared. Here, accuracy is crucial because precise molds are needed to create consistent curbs that are uniform in size. To ensure a sturdy and solid product, the concrete mixture is poured into these molds and vibrated to eliminate any air pockets.

The curbs go through a curing process after molding. In order to achieve the required strength and durability, this stage is essential. The curbs are maintained in a controlled environment so that the concrete can properly harden over several days. The curbs are routinely inspected during this time to make sure they are positioning correctly.

Step Description
1. Raw Material Selection Choose high-quality concrete and additives to ensure durability and strength.
2. Mixing Mix the raw materials thoroughly to achieve a uniform consistency.
3. Molding Pour the mixture into molds to shape the curbs as desired.
4. Curing Allow the molded curbs to set and harden, ensuring they gain the necessary strength.
5. Finishing Apply any surface treatments or textures for aesthetic and functional purposes.
6. Quality Control Inspect the finished curbs for any defects and ensure they meet the required standards.
7. Packaging and Shipping Package the curbs securely and prepare them for transport to the installation site.

Materials for fencing

Road curbs come in different materials from factories and are given away for free. Let’s examine each in more detail.

Heavy concrete

Compressive strength class of at least B30, frost resistance grade of F100, and water resistance grade of W are required for the material. Large filler is made of crushed granite with a granulometric composition of 20–30 mm.

Benefits

  • high strength and reliability;
  • wide distribution on the market;
  • maintainability.

Drawbacks:

  1. increased dead weight;
  2. complexity of the device for preparing and installing products.

Expanded clay concrete

Ideal for producing lightweight curbstones, which are typically installed in cottage villages and other places with little traffic.

Benefits

  • light weight;
  • reasonable price;
  • easy to install without the use of heavy equipment.

Drawbacks:

  1. low frost resistance and impact strength;
  2. increased porosity, which contributes to rapid penetration of moisture.

Natural granite

Utilized in the design of park squares, roads in historic city centers, and landscaping features in upscale residential and public complexes.

Benefits

  • the highest strength class;
  • attractive appearance;
  • water absorption no more than 0.5%.

Drawbacks:

  1. high price;
  2. complexity of cutting and installation;
  3. require a capital foundation.

Sinter stones

Goods produced by vacuum pressing a polymer binder as their foundation. The following substances are suitable for use as filler:

  • marble or granite chips;
  • mica;
  • labradorite.

Benefits

  • the products have almost the same strength and physical and mechanical characteristics as granite stones, but are much cheaper;
  • a wide variety of textures and colors.

Drawbacks:

  1. complexity of installation;
  2. the weight of a standard agglomerate curb with dimensions 1000 x 300 x 180 is at least 150 kg.

Polymer concrete

A relatively recent material that is frequently used on individual plots, internal driveways, and surrounding areas.

Benefits

  • easy processing and installation;
  • small bulk weight;
  • high frost resistance and water resistance;
  • wide variety of colors.

Drawbacks:

  1. can be easily dismantled by vandals;
  2. require restoration of the shade after several seasons.

Natural cobblestones, wooden beams or logs, as well as metal or plastic curb pieces, are frequently laid by landscape architects. Private plot owners are able to create curb stones by hand using leftover materials.

In order to guarantee longevity and functionality, precise procedures are used when producing road curbs. Every step is important, from choosing the proper concrete mix to forming and curing the curbs. This article will examine every stage of the manufacturing process, emphasizing the value of high-quality supplies and techniques in the creation of dependable road curbs that can withstand weather and traffic.

Necessary equipment for manufacturing

Using the materials mentioned above, the following categories of electrical and manual equipment are needed to create road curbs:

  • Work table with vibration supports, to enable high-frequency compaction of materials.
  • Side prefabricated formwork, or ready-made forms for pouring curbs.
  • Molds with punches and matrices, in the manufacture of products by the method of semi-dry vibration pressing.
  • Concrete mixing unit with automatic dosing of main components, plasticizers and pigments.
  • Bunker for feeding ready-mixed concrete into a mold.
  • Hoists and overhead cranes for transporting finished products, placing them on a pallet.
  • Autoclave furnace for curing freshly laid concrete in molds to gain strength.
  • Wrapping station for finished products, multiple pallets.
  • Spot welding station for manufacturing reinforcing frames for some types of products.
  • Band saw equipment, grinding and polishing station – for manufacturing and finishing granite curbs.
  • Vacuum pressing station with a furnace, in the manufacture of vibration-pressed or agglomerate curbs.
  • Test bench with a press for testing the strength of random samples from a batch after manufacturing.
  • Label and barcode printing station for marking a batch of curbs before sending to the consumer.

Every machine needs to be in good operating order, free of debris and dust, mold-free, and with sufficiently productive electric motors. Setting up an automatic return line in the workshop with pallets and magnetic formwork would be the best way to arrange large-scale production.

Creation technologies

Various manufacturing technologies are available for road curbs, contingent upon the materials employed:

  • Casting method of manufacturing products – liquid concrete is placed in formwork, after which the material is sent to an autoclave oven to gain strength.
  • Vibropressing – forming stones from a rigid cement-sand mixture with coarse aggregate without formwork, using molds.
  • Combined method of casting in formwork and vibrocompression.
  • Mechanical processing of raw stones – for the production of granite borders.

Every technology has its own set of manufacturing equipment, formula for materials, methods of control, and duration of production.

Requirements for organizing a workshop

In order to manufacture road curbs for commercial use, a workshop space that satisfies the following requirements is necessary, regardless of the technology employed:

  • The area of ​​the covered premises must be from 250 m2 and more.
  • The height for free movement of the crane beam above the autoclave furnace must be at least 5 m.
  • Gates are organized at the ends of the building – a zone for loading raw materials and shipping finished products to the warehouse.
  • Equipment for the production of curbs must ensure a continuous production cycle. Machine tools are installed sequentially, one after another, with the line equipped with transport trolleys for moving products between posts.
  • The autoclave unit must have sufficient capacity to accommodate a whole batch of products so as not to interrupt the production process during strength gain.
  • The hopper for feeding concrete mix must move freely from the concrete mixing plant to the molding post on rails.
  • It is recommended to install a module for automating production lines.
  • On the street side, it is required to provide two cold warehouses for storing inert materials, install a cylindrical can for cement, and also fence off a separate area for placing pallets with finished products.
  • For correct mixing of inert materials in the cold season, an additional heating post should be installed.
  • To ensure full control over the consumption of inert materials and cement binder, it is necessary to install scales with tensors in the area of ​​the receiving bin of the mixing plant.
  • The workshop should have exhaust ventilation with filtering equipment to ensure the required air exchange rate and clean the room from dust.

The workshop should designate spaces for staff rest, clothes changing, showers, and an office for the shift supervisor in addition to the areas already mentioned.

Step-by-step instructions for making with your own hands

You must finish each step of the following process map in order to create cast curbstones by hand:

  • A mold for the future curbstone is assembled on a horizontal surface. The mold should be designed in such a way that the front face of the future product with a chamfer is in its lower part.
  • The flange is lubricated with oil from the inside, which eliminates the adhesion of hardened concrete to the walls of the formwork.
  • If necessary (if the future curbstone has a length of more than 1000 mm), it is necessary to lay a flat reinforcement frame in the form with fixation of its position.
  • Concrete mixture is fed into the form, which is distributed over its volume by ramming.
  • After molding, it is necessary to compact the concrete on a vibrating table, or using a deep vibrator with a mace.
  • The free surface of freshly laid concrete is smoothed until a flat plane is achieved.
  • The concrete is kept in the formwork for a standard time period.
  • After setting and the beginning of hardening, the formwork is disassembled, and the finished product is removed to continue gaining strength.

It should be remembered that, if the products are stored at a positive temperature, concrete gains design strength for at least 28 days in the absence of an autoclave. Curbstone installed and transported before this time may be destroyed by mechanical impacts.

Is certification necessary?

As there is no increased risk involved in using these products, curbstone does not need to be certified at the state level.

Many manufacturing companies use this certificate as part of their marketing strategy and competitive edge, and it also attests to compliance with GOST requirements.

Technical conditions are developed that specify the future product’s technical features and molding technology based on existing regulations. Prototypes are tested in specialized labs following the release of the first batch, and following this, official certificates of compliance with TU are issued by government agencies.

Every batch of products that the manufacturer produces has a quality certificate attached to it that contains the product’s current certificate of conformance number.

Useful video

Extra details regarding the production:

Road curb production is a meticulous process that guarantees longevity and durability. Making high-quality curbs requires careful consideration of every step, from material selection to molding techniques.

Knowing these procedures enables us to recognize the skill and technology at play. Every element, from the concrete mix to the curing procedure, needs to be carefully considered.

Purchasing high-quality road curbs is an investment in our streets’ appearance and safety. Reliability of the entire infrastructure is enhanced by the use of high-quality production techniques, which also improve curb functionality.

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Andrey Ivanov

Experienced civil engineer with more than 20 years of experience. Specializing in the construction of industrial and civil facilities. Author of many publications in professional journals.

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