How to make a float or plane for aerated concrete with your own hands – a step-by-step plan

For your upcoming project, are you trying to achieve a smooth finish on aerated concrete? For both pros and do-it-yourselfers, knowing how to create a float or plane for aerated concrete can be quite useful. Because of its lightweight and insulating qualities, aerated concrete requires a particular finishing technique to look professional. You can customize a homemade float or plane to meet your requirements and get high-quality results.

Prior to delving into the detailed procedure, it is imperative to grasp the fundamentals. Aerated concrete, also known as autoclaved aerated concrete (AAC), is created by adding an expanding agent to a mixture of cement, lime, sand, gypsum, and water, causing bubbles to form in the mixture. The concrete is lighter and more thermally insulating than conventional concrete because of these bubbles, which also give the material its porous structure.

Making a float or plane requires making a tool that is intended to level and smooth the aerated concrete’s surface. Although there are commercial floats and planes available, creating your own allows for cost-effectiveness and customization. Sturdy but lightweight materials are used in the process to ensure durability and ease of use.

Let’s now go over the detailed process for making your aerated concrete float or plane:

1. Select Your Resources: Select materials that are balanced in terms of weight and strength. Popular options include magnesium, aluminum, and wood. For the finish to be perfect, make sure the edges are smooth and straight.

2. **Shaping and Cutting:** Take measurements and cut the selected material to the appropriate size. For the initial smoothing of a float, a larger surface area is better. For more accurate leveling, a plane’s surface area is usually smaller. To avoid digging into the soft, aerated concrete, slightly round the edges.

3. **Introductory Note:** Choose a handle that will allow you to control and grip the float or plane comfortably while using it, based on its size. This could have a prefabricated handle for convenience or a wooden handle for a handmade look.

**Concluding Remarks:** To avoid leaving any inadvertent marks on the concrete surface, make sure all surfaces are smooth and sand down any sharp edges. A well-made plane or float will skim the surface without producing any flaws.

You can make a float or plane that meets your unique requirements for working with aerated concrete by following this methodical plan. Having the appropriate tool for the job ensures a professional finish that improves the project’s aesthetic and functional aspects, whether you’re smoothing walls, floors, or other surfaces.

What is a plane for

The surface of aerated concrete blocks isn’t always level. A defective block must have its surface leveled in order to be used for work. Having a plane will make this task easier.

The fineness of the masonry will be compromised if the surfaces are not leveled. When the aerated concrete blocks are placed on glue, recognized standards state that the seam between them shouldn’t be wider than 1.5 mm. The masonry will be skewed if the flaw is not fixed.

Those who plan to live in an aerated concrete home should consider this.

Types of planes

The kind of cutting surface used in each type of plane design varies.

• saw blades;
• nail plates.

Little-toothed saws are used in the first instance. When leveling the surface of blocks with a density of no more than 500 kg/m³, such a tool is quite useful. The quantity of saws installed varies and is solely determined by the tool’s manufacturer.

The tool typically has up to ten cutting saws installed. Furthermore, they are dispersed equally across the plane’s two sides. The saws should be angled at a 65º angle for optimal processing.

The nail plates that are fastened with unique screws serve as the cutting tool for the second variety of planes. There are occasionally homemade versions of planes available, such as a cutting plane with a coarse sandpaper cutting surface. However, this kind of tool is useless because the sandpaper becomes useless very quickly due to clogging. It will be more profitable to buy an aircraft from a store because the costs are too high.

If an electric motor is installed in an aerated concrete plane, its efficiency will increase multiple times. A basic hand plane is utilized for smaller quantities of work.

Electric

Unquestionably, an electric float for aerated concrete has one benefit. When it is used, labor productivity and quality are far higher than when a hand tool is used.

The installed motor’s power determines the product’s productivity. The plane’s motor should not have more power than 1000 W.

You need to wear a respirator when using an electric tool because not all designs have a dust collector. The tool knives should only be sharpened by professionals. An electric knife sharpener is occasionally included with the electric plane.

Manual or mechanical

Compared to their electric counterparts, hand planes are utilized far more frequently. There is a good selection of this design of device in stores. There are models composed of plastic, metal, and wood.

Typical design

These gadgets share the same design. Every one of them has a working surface and a handle. The location of the cutting elements determines the tool’s quality in every way. It will not be possible to restore the block if a significant portion of it is removed during construction. As a result, selecting a tool requires extra consideration.

The strength of the material used for the tool’s base and cutting portion is its primary requirement. It will be challenging to use this tool if the plane is difficult to move along the block’s surface. Industrial planes have a longer service life than homemade ones, which is their main advantage.

In Moscow, purchasing an aircraft to use with aerated concrete blocks is simple. Numerous shops are available to assist you in selecting the best choice.

Features of a hand plane

The grater principle forms the basis of the plane. The positioning of the cutting surfaces causes the block’s surface to be worn down when the product moves. A wood plane’s cutting element has a different angle than an aerated concrete block, so deformations will occur on its surface if you use a simple plane to process it. The purpose of the aerated concrete tool is to remove surplus, not to cut.

This implies that the device should be able to remove a clean layer in a single motion without damaging the surface. It’s important to select hand planes carefully when purchasing them in a store. The sole of a good tool must have a minimum width of 110 mm. You ought not to select bulky items. Tools that weigh no more than 3.5 kg are ideal for working with aerated concrete.

This article from "All about Concrete" will walk you through the process of making a float or plane made especially for aerated concrete, using easy-to-follow step-by-step directions. Although aerated concrete is a lightweight and adaptable building material, the proper equipment and methods are needed to achieve a smooth finish. In addition to saving money, creating your own float or plane guarantees that you have a tool that fits your needs. This guide will help you complete your aerated concrete projects with professional-level results, improving both efficiency and quality, whether you’re a DIY enthusiast or a professional.

How to make it yourself

Making an aerated concrete plane with your hands is not hard at all. Additionally, the cost of the raw materials will be minimal. The caliber of the work will be on par with the samples provided by retailers. You can make an aerated concrete grater with your hands in a number of ways.

Selecting the cutting elements is a must before manufacturing can begin. It is sufficient to process aerated concrete to a depth of 2 mm.

As a cutting element, self-tapping screws can be installed in place of saws. Subsequently, the device’s base is constructed in the same manner as with saws. Additionally, marking is done. Self-tapping screws are inserted at a 30º angle using a screwdriver. One row of self-tapping screws has an inclination that is the opposite of the preceding row’s.

The self-tapping screws must be inserted so that they protrude 2 mm from the back when they are fully inserted. The handle is then fashioned. By building your own aerated concrete plane, you can save half the price of a tool purchased from the manufacturer.

Preparation of materials and tools

It is preferable to base the future product on wood. The ideal board has a thickness of roughly 5 cm. The tool’s base should measure between 50 and 60 cm in length and 15 cm in width. The best boards for a plane are made of beech, oak, and hornbeam.

Parts are cut with specific saws. You should consider the density of the aerated concrete you will be working with when selecting them. Using woodworking blades on concrete is acceptable as long as its density is less than 500 kg/m³. Three of these wood saws are sufficient for projects at home. Additionally, glue is required for the task.

• a jigsaw, preferably electric;
• sandpaper;
• a file;
• a grinder;
• a brush;
• a marker.

You must choose a handle that is comfortable for a plane. Your hands will feel less fatigued the wider it is. One wooden block is used to make the handle. It is given a curved form. Self-tapping screws can be used to fasten it to the base.

A lot of skilled artisans suggest painting the product white. This should be done to prevent the homemade tool from discoloring the block surface while being used.

The location where the saws are fastened is the weakest point in the entire construction. Bolts cannot be used to secure the saws. The metal will need to be drilled for this. But this is not a chance that every craftsman gets. Glue is the only method of attachment for these. Additionally, the glue is made to function with a variety of materials.

Marking

From the prepared block, a block of the desired length is sawed off. It has rounded corners. Sandpaper is used to level the surface. The saws’ precise location on the base needs to be marked. If not, the tool’s efficiency will decline.

Five parallel lines are drawn to indicate the base, and each segment’s distance from the other must be equal. A 70º angle is maintained between the lines and the longitudinal portion. The slope on the right side should be to the right. To the left, on the left side. It will become apparent that they are oriented toward one another after the cutting components are installed.

Cutting

To continue, you’ll need a jigsaw. They cut to ensure that the saw fits perfectly in the designated spot. Sawing must be done from both sides, repositioning 2-3 centimeters beforehand. If the saw is longer than necessary, a portion of the necessary size will break off.

Gluing

The tile’s surface is covered in a layer of glue. Subsequently, the blades are placed vertically into the slots that have been made for them. Glue needs to be applied to the area where the cutting elements will be positioned. Give it the necessary amount of time. The glue has to set up nicely. You can only check the saws’ level of security after this. After that, you can begin fastening the handle. It is best to sharpen the cutting elements before beginning work.

Additional device

Additional devices that prevent the surface of the blocks from being erased too deeply can be installed on the plane to prevent spoiled aerated concrete blocks during the leveling process. For novices who must work with cellular concrete for the first time, this tool will be extremely helpful. The device has slats attached to it that serve as guides.

It is important to keep in mind that the slats should not extend past the block’s boundaries when installing them. They must not be any smaller than the block, either.

The length of the fasteners must be taken into consideration when determining the device’s dimensions. The bars must be positioned such that they perfectly align with the aerated concrete’s edges.

Two boards that are 2-3 cm thick are needed to create such a helpful device. Sand the board edges and corners.

Step	Description
1	Gather materials: aerated concrete blocks, cement mortar, water, tools.
2	Prepare the base: ensure it"s clean, level, and able to support the weight.
3	Mix the mortar: follow instructions for the right consistency.
4	Lay the first layer of blocks: apply mortar to the base and edges of blocks.
5	Check alignment: use a level to ensure blocks are straight and even.
6	Add subsequent layers: repeat mortar application and alignment checks.
7	Finish the top layer: cut blocks if necessary to fit neatly.
8	Allow curing: let the structure dry and set for recommended time.
9	Optional finishing: apply finishing coat or paint as desired.

If you’ve been thinking about using aerated concrete for your construction projects, building your own float or plane is a doable method to guarantee accuracy and control. Through a methodical approach, you can create a tool that is tailored to your individual requirements and inclinations.

First, before you start, make sure you have all the required supplies and equipment. This involves using a flat, strong wooden plank or board that can endure the pressures of smoothing aerated concrete. You’ll also want a handle or grips that are easy to hold and offer good control when in use.

Next, take a measurement of the float or plane’s dimensions and mark them on the wooden board. Here, accuracy is crucial because the tool’s precise dimensions and form determine how effective it is. To guarantee accuracy, mark the location of the smoothing edge and the handle attachment points with a pencil and ruler.

After marking, use a saw or other suitable cutting tool to carefully cut out the shape of the float or plane. The tool’s performance may be impacted by inaccuracies, so take your time and follow the lines precisely. Using sandpaper, smooth out any uneven surfaces to produce a smooth finish that won’t snag or harm the aerated concrete.

Once the basic shape is smoothed and cut, firmly fasten the handle to the board. This could involve adhesive, bolts, or screws, depending on your design. You’ll be using the handle a lot when working with concrete, so make sure it’s securely fastened to the board and fits comfortably in your hand.

Lastly, think about giving the wooden board a protective coat before using your homemade float or plane. This prolongs the tool’s life by preventing moisture absorption. Adding a layer of paint or varnish can also make it simpler to clean the tool after use, extending its useful life for additional tasks.

When you have your customized float or plane ready, you can manage aerated concrete with assurance and accuracy. Frequent upkeep, like cleaning and sporadic refinishing, will guarantee that your tool stays in top shape for many years to come. You can save money and improve your ability to complete concrete projects with a professional finish by devoting some time to creating a tool that meets your specific needs.

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