Production of concrete tiles: main features and stages of production

Concrete tiles are a strong and adaptable material that can be used for a number of building applications, including roofs, floors, and even accent walls. Their strength, durability, and aesthetic adaptability make them a popular option for both commercial and residential applications. Comprehending the manufacturing procedure of concrete tiles can aid in recognizing their worth and guaranteeing their appropriate application.

There are multiple important steps in the production of concrete tiles, all of which are necessary to guarantee the end product’s durability and quality. The method begins with the meticulous selection of raw materials, which usually consist of water, sand, cement, and occasionally additives for improved qualities. The precise ratios of these ingredients are combined to create a uniform and workable concrete mix.

The concrete mixture is prepared by pouring it into molds that specify the dimensions and form of the tiles. These molds can be altered to create a vast variety of patterns and textures, meeting a variety of functional and aesthetic requirements. After the molds are filled, the concrete must undergo a curing process that entails keeping the proper temperature and moisture content throughout time for the concrete to solidify and become stronger.

The tiles are meticulously taken out of the molds after they have cured and go through additional finishing procedures. To improve their appearance and longevity, surface treatments like painting, polishing, or applying a protective sealant can be applied. Every step of the process involves quality control checks to make sure the tiles fulfill the necessary requirements and standards.

Packing and getting the tiles ready for delivery to their destinations is the last step. To avoid damage and maintain the quality of the tiles until they are ready to be installed, proper handling and storage are crucial. Concrete tiles can provide a dependable and eye-catching answer for a range of construction requirements with the correct manufacturing methods and meticulous attention to detail.

Types of concrete tiles and their scope of application

Undoubtedly, sidewalks come to mind for many when discussing this material. Yes, this is the most typical use case for these kinds of products.

According to GOST, the shape of concrete tiles can determine several types of them:

1. Rectangular
2. Hexagonal
3. Figured
4. Bordering
5. Square
6. Decorative

Other categories exist as well. For instance, tactile tiles can be used to pave roads meant for individuals with disabilities. Its surface is rough and slightly convex.

Facade concrete tiles

If we are discussing concrete in general rather than paving slabs, it is important to consider the facade option. Although it hasn’t been around for very long, this technique of finishing a building’s exterior is now highly desirable.

Concrete tile facades have the following obvious benefits:

• The material is durable and long-lasting.
• The variety of shapes and sizes will not leave any potential buyer indifferent.
• The tiles have excellent water-repellent properties.
• Aesthetics. The facade when finished with this material will have a presentable appearance.
• Quite an attractive price. The cost of the cladding will be significantly lower than, for example, when using porcelain stoneware, brick or other material similar in strength and performance characteristics.
• Possibility of combination with other building materials. Concrete facade tiles go well with almost all products suitable for cladding.

Kevlar concrete tiles

Ultra-concrete, also known as kevlar concrete, is a recent development in the market for building supplies.

• special strength, reaching 600 kg/m3;
• excellent performance characteristics;
• specific production process, in which, using a gravity concrete mixer, air is completely removed from the solution;
• aesthetic appearance;
• versatility in application.

In addition to paving slabs, Kevlar technology is used to make fences and other ornamental building products. Although the cost of this material is relatively high, its resistance to external factors and durability can satisfy even the most optimistic expectations.

Types of manufacturing technologies

Concrete tiles are currently made using two primary techniques: vibration pressing and vibration casting.

Let’s examine each approach in more detail:

1. When producing tiles using vibratory casting, the finished mixture is compacted in special molds using fairly intense vibration movements. Then they are placed in a warm room for some time, equal to approximately several days. After removal, finished products can be sent to the warehouse.

The materials for this method are assumed to be as follows: one part cement grade 500 and two parts aggregate. In this instance, the raw material is delivered dry to the concrete mixer, and water is added only after mixing.

A plasticizer is added to the mixture to improve quality and performance characteristics, resulting in smooth and even products.

1. Vibration pressing is distinguished mainly by the complete automation of the production process, as well as a high level of productivity due to the almost complete absence of human labor costs. All manufacturing stages are carried out by machines.

Each ingredient is added to a separate container and combined there. At the output, final products are obtained after the solution is pressed with a press.

According to this method, there should be one part grade 500 cement and three parts filler. There is as little liquid added as feasible. This article’s video provides details on these kinds of manufacturing. The tinting method can be used to give the tile a specific shade. The primary guideline in this instance is that the color should not make up more than 5% of the solution’s overall mass.

The final products don’t differ much; both the first and second approaches are effective in their own right. As a result, you can use any of them to obtain high-quality products.

It would be accurate to state that they exist within the competition, meaning that each manufacturer makes an effort to set their products apart by making them unique from the competition. Using a unique manufacturing process to carry out such a marketing strategy would make the most sense.

Every owner of a yard, garden, or other space wants to buy the best, most long-lasting products possible, made with the newest technologies. Yes, it does work!

Comparison of products manufactured using different types of production

The following table will be used for comparison: variations among products manufactured with various technologies:

Indicator	Vibration pressing	Vibration casting
Appearance and main properties	The surface is slightly rough, which makes it possible to pave sidewalks.

Necessary equipment for manufacturing products

The list of equipment you will need to buy to begin manufacturing will vary based on the production conditions and will be covered in the section below. It is worth considering because the process of buying machines for the plant will be more expensive and labor-intensive.

Technical equipment for production in factory conditions

The minimal group includes:

• Concrete mixer
• Tile molds
• Pouring vibrating table
• Stripping vibrating table for releasing finished products.

The price of this list varies from 10 to 500 thousand rubles based on the manufacturer and equipment condition. The best choice, though, is to buy a production line that is already built. Although it is far more expensive than the earlier choice, the production return is likewise higher.

The machine’s versatility is a major benefit. You can set up the production of materials with comparable compositions and qualities, in addition to concrete tiles, with its assistance. For instance, brick and stone.

You will also require a loader, trolleys, shovels, a transformer, and other small items to increase automation and expedite production in addition to a stationary vibrating press.

List of inventory and raw materials for independent production of products

Only the vibration casting method can be used to obtain DIY concrete tiles.

You’ll need the following supplies for this:

• Concrete mixer
• Tile molds, mainly made of rubber or plastic.
• Strong racks for placing finished products on them.
• Vibrating table
• Lubricant for processing molds

The materials needed are also few in number; you will need:

• Cement, at best grade 500
• Plasticizer
• Fiber
• Color
• Water
• Filler. This can be sand or fine granite screenings

It is simple for those who intend to arrange small-scale production to assemble their own vibrating table. The process is straightforward, and in addition, the equipment can be sold off if it becomes unnecessary in the future. You will need hardware, a tabletop board, an electric motor, and a variety of metal products in addition to the instructions for this.

One of the two vibration modes that the vibrating table can have is either vertical or horizontal. Because of its simplicity of use, the latter is the most preferred.

They are separated into two categories: portable and stationary installations. Additionally, by specialization—stripping and molding.

Stages of tile production

It’s time to examine the actual production process now. First, let’s discuss the option that can be produced independently.

Work order for home production

Now that you have the required tools and supplies, you can get to work.

This is how the order will appear:

1. First, you should prepare the forms. For this, they are lubricated with a special compound.
2. Preparation of the solution. Since this is the key to the quality of future products, this stage should be approached responsibly, observing the order of laying and proportions of raw materials.

In a concrete mixer, add one part cement and two parts filler. Add the fiberglass after the mixture is dry. Plasticizer and pigment are combined ahead of time and added to water in a 1:4 ratio.

1. The next step is to make the tiles themselves. The molds are placed on a vibrating table and the solution is poured into them. After this procedure, the blanks are transferred to shelves and, covered with plastic wrap, left to dry for 2-3 days.
2. After this period of time, the tiles can be removed from the molds. To facilitate the process, they are dipped in warm water at a temperature of about 60-70 degrees and then, lightly tapping with a rubber hammer, knocked out.
3. The tiles can be used for laying paths only after a month. Until this time, the material gains strength.

Factory production

As previously stated, the vibration pressing method is the best choice for producing tiles under factory conditions.

The steps of the procedure are as follows:

• Raw materials are supplied along separate production lines for subsequent mixing in the required order.
• The finished mixture is fed under the punch, which, descending, presses the concrete mixture and gives it a given shape. At this time, vibrators are turned on, affecting the process of compaction of concrete. This stage takes no more than 5 minutes.
• Then the tile is moved to specially equipped rooms, where it is processed with steam.

The punch is patterned in a specific way. It is etched on goods to come.

Semi-dry vibration pressing and semi-dry hyperpressing are further subdivided under this production type. The distinction is that in hyperpressing, compaction is accomplished by high pressure rather than vibration.

As was already mentioned, this kind of production is fully automated, enabling the creation of tiles in sizable quantities.

Be aware that there are a lot of misconceptions about how contemporary tile production machines work, their high cost, and how difficult it is to maintain them. This isn’t totally accurate, though. Training staff only takes a few days due to the basic nature of the line control concept. Additionally, the equipment’s cost will be recovered rather quickly if sales markets are available and the scale is adequate.

A simple but exact process is used to produce concrete tiles, guaranteeing their longevity and visual appeal. Preparing the concrete mix, shaping the tiles into the appropriate shapes, curing them to attain maximum strength, and finishing them to give them a polished appearance are the key steps. Making tiles that are not only sturdy and long-lasting but also aesthetically beautiful requires careful attention to every detail, from choosing premium materials to applying surface treatments. Recognizing these phases makes it easier to appreciate the artistry that goes into each concrete tile.

Advantages and disadvantages of products

Both advantages and disadvantages can be associated with concrete tiles. Furthermore, even with their widespread use, they continue to prompt some yard owners to consider using different materials.

Let’s investigate whether their drawbacks really are that bad.

Advantages of concrete tiles

Let’s begin with the benefits:

• A huge selection of shapes and sizes, thanks to which you can create unique designs that can decorate any area
• High level of resistance to biological and climatic influences, including sudden changes in temperature.
• Relatively low cost of products
• Concrete tiles are slightly susceptible to abrasion and easily withstand mechanical loads
• The material is environmentally friendly, which is especially important for modern realities.
• Easy to lay, replace and repair.

In short, concrete tiles satisfy the needs of economy and practicality and possess all the attributes required for comfortable and long-lasting use.

Disadvantages of products

Of course, negative aspects are also unavoidable.

Essentially, they are as follows:

1. When manufacturing tiles using vibration casting, the products are very slippery, so their scope of application is quite limited for safety reasons.
2. Often, the service life of the tiles is somewhat shorter than stated by the manufacturer. This fact takes place if the tile is made in a region whose climate is different from the weather conditions in the city receiving the product.
3. If there are installation errors, they are difficult to correct. The tiles may be subject to deformation, become covered with cracks and give serious shrinkage.

This is where the drawbacks become less pronounced, and the benefits are clearly greater. Furthermore, under the influence of legitimate benefits, the negative aspects might go completely unnoticed if you focus on the qualitative rather than the quantitative.

Technical and economic component of the concrete tile manufacturing business

Where to start a business?

Naturally, registering a business, creating a budget, and drafting a business plan come first.

The business plan ought to include detailed information regarding:

• the procedure for purchasing equipment, its cost
• raw material costs
• electricity and water supply costs
• salary calculations and all kinds of deductions
• rental costs of both production and office premises

In addition, one needs to factor in unanticipated costs and household necessities. Selecting the best production model and equipment line in advance is worthwhile. This is mostly dependent on the monetary component; the income increases with the size of the contribution.

Let us examine the potential course of events based on production volume and determine the profitability of the production for both developers and business owners.

Calculation of production profitability

An estimate of the cost-effectiveness for producing tiles on one’s own

Expenses for the purchase of equipment
Name	Quantity	Unit cost	Total cost
Vibrating table	1	25000	25000
Concrete mixer	1	16000	16000
Molds for pouring concrete tiles	15	1800	27000
Other additional equipment: shovel, buckets, racks, scales	—	—	15000
Total expenses: 83000
Raw material costs, taking into account per 1 m2
Cement M500	15 kg	5	75
Filler (fine fraction crushed stone)	52 kg	1	52
Water	10 l	0.15	1.5
Plasticizer	0.35 kg	40	14
Dye	0.28 kg	80	22.4
Total expenses for production of 150 m2: 107735

The final tile cost for a 150 m2 volume is 57,000.

Kindly take note! As you can see, buying every piece of equipment needed for a single production case is not financially viable. Additionally, building the machines yourself is advised if you still want to attempt producing tiles on your own.

Calculation of revenue and costs for a company that uses an automated line to produce concrete tiles:

Expenses for the purchase of equipment
Name	Quantity	Unit cost	Total cost
Full set of automated equipment with inventory	1	1500000	1500000
Total expenses: 1500000
Raw material costs, taking into account per 1 m2
Cement M500	15 kg	5	75
Filler (fine crushed stone)	52 kg	1	52
Water	10 l	0.15	1.5
Plasticizer	0.35 kg	40	14
Dye	0.28 kg	80	22.4
Total expenses per month assuming production of 9000 m2: 1484100
Electricity costs: 150000
Payroll: 900000
Rent of premises: 120000
Advertising: 10000
Deductions to the Social Security Fund: 30000
Transportation costs: 10000
Urgent needs: 10000
Calculation of income from product sales
Cost of 1 m2 of tiles: 164.9
Retail price; 380
Profit from 1m2: 215.1
Profit for 1 month when selling 9000 m2 of tiles: 1935000
Tax=15%: 289485
Net profit per month: 1645515

Estimating the profitability of small-scale manufacturing using the lowest possible quantities of manufactured goods:

Expenses for the purchase of equipment
Name	Quantity	Unit cost	Total cost
Vibrating table	1	25000	25000
Concrete mixer	1	16000	16000
Molds for pouring concrete tiles	150	1800	270000
Other additional inventory: shovel, buckets, racks, scales	—	—	50000
Total expenses: 361000
Raw material costs per 1 m2
Cement M500	15 kg	5	75
Filler (fine crushed stone)	52 kg	1	52
Water	10 l	0.15	1.5
Plasticizer	0.35 kg	40	14
Dye	0.28 kg	80	22.4
Total expenses per month assuming production of 1200 m2: 197,880
Electricity costs: 60,000
Payroll: 90,000
Rent of premises: 40,000
Advertising: 10,000
Contributions to the Social Security Fund: 30,000
Transportation costs: 10,000
Urgent needs: 10,000
Calculation of income from product sales
Cost of 1 m2 of tile: 164.9
Retail price; 380
Profit per 1m2: 215.1
Profit per month when selling 1200 m2 of tiles: 258120
Tax=15%: 38718
Net profit: 219402
The payback period will be approximately 4-6 months, depending on monthly optional costs.

A little about the use and laying of tiles

The following procedures must be followed in order to pave with concrete tiles on a concrete base:

• preparatory work includes: drawing up a clear plan, marking the territory, work related to the top layer of soil. First, the required amount of material is calculated and drawings are made. Then markings are made in accordance with the above data. All plants and rhizomes are removed from the soil; it is leveled and sprinkled with a special layer that acts as a cushion.
• Tiles are laid starting from the corner, focusing on the axis.
• Tiles are sunk with a rubber hammer in order to shrink them.
• Work should be carried out in the direction away from you, in order to exclude loads on the laid material.
• The solution is distributed evenly, paying special attention to the seams: they must be filled.
• After laying, the tiles are watered with cold water so that the solution is not washed out of the seams.
• It is not recommended to install more than 3 m2 of tiles at a time.

There are a ton of ways to arrange the material. Everybody is free to select their own pattern. A blend of various hues and forms is particularly appealing.

Main Features	Stages of Production
Durable and long-lasting	1. Mixing the concrete
Weather-resistant	2. Pouring into molds
Available in various designs	3. Vibrating to remove air bubbles
Low maintenance	4. Curing and drying
Eco-friendly options available	5. Quality inspection

The process of creating concrete tiles is an intriguing one that blends science and art. Comprehending the primary attributes and phases of manufacturing facilitates the appreciation of the artistry inherent in every tile. To guarantee the tiles’ longevity and visual appeal, every stage—from choosing the appropriate materials to conducting the last quality inspection—is essential.

Choosing premium raw materials, such as cement, sand, and aggregates, is the first step in the process. In order to produce a reliable and robust base, these ingredients are precisely measured and combined. Subsequently, the blend is transferred into molds that can be tailored to yield diverse forms, dimensions, and surface finishes. Concrete tiles are a popular option for many projects because of their flexibility, which opens up a wide range of design possibilities.

The tiles go through a curing process after molding. This phase is crucial since it establishes the ultimate product’s durability and strength. The tiles will be able to endure environmental stress and hold their appearance over time if they are properly cured. The last stage entails adding finishing touches that improve the look and longevity of the tiles, like polishing or applying protective coatings.

Producing concrete tiles involves more than just making building materials that work; it also involves meeting performance and design standards. Every step, from choosing the right materials to applying the finishing touches, is carefully done to create tiles that are both elegant and robust. One can more fully appreciate the usefulness and adaptability of concrete tiles in building and design by being aware of this process.

Video on the topic

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