Paving slabs. Types and technology of manufacturing paving slabs.

Production of vibro-cast paving slabs

To make vibrating cast tiles, you need simple equipment such as a concrete mixer, a set of molds (which can be made of silicone, polyurethane or plastic) and a vibrating table. It can be made in artisanal conditions.

vibrocast paving slabs

These paving slabs are made from a concrete mixture that includes fine crushed stone, cement with sand, a plasticizer and a coloring pigment with water. In addition to the listed components, you can add other materials, such as granite or basalt chips, fiberglass, fiberglass, and some products are reinforced with wire mesh to increase strength.

Molds filled with concrete mixture are installed on a vibrating table, during which the remaining air is removed from the mixture in the molds and the composition itself is compacted. The product gains strength within three to five days, then the finished product is removed from the molds and dried for three weeks until it can be used.

Vibro-cast paving slabs

Price segment - economy

Vibratory cast paving slabs are made using simple equipment - a concrete mixer, a vibrating table and a set of plastic molds. This is a completely manual production method

, which is carried out, as a rule, in makeshift or “garage” conditions. There are a considerable number of similar “productions” of paving slabs in each region.

Not only a specialist, but also anyone can produce tiles using the vibration casting method - that’s why the request “ do-it-yourself paving slabs”

" On the Internet you can find a huge number of offers of plastic molds (the price of the mold ranges from 1000 to 2000 rubles), as well as proven “recipes” for making paving slabs at home.

During the manufacturing process, a mixture of sand, cement and water is loaded into molds and compacted on a vibrating table. Next, the forms with the products are transferred to racks for storage. At the same time, the conditions for gaining strength are not controlled; the productivity of this manual production method is extremely low. The resulting vibrocast tiles often have strong deviations in height, which makes it difficult to lay the stone in the future.

Vibro-cast tiles are a frozen mortar mixture without coarse aggregate, which does not allow it to have high strength and frost resistance parameters. Due to the high water content, the tiles have high porosity

.
During the winter period of operation, due to frequent temperature changes, which is especially important for the climatic conditions of the North-Western region, water enters the existing pores and, through its wedging effect, destroys the structure of the concrete. The service life of vibrocast tiles is on average 2-3 seasons without visible signs of destruction
.

Despite the serious disadvantages of vibrocast tiles (low strength and durability), the products are in demand due to a number of objective advantages: low price, a huge variety of molds and bright colors obtained due to high dosages of coloring pigments. Vibro-cast tiles can be used for paving paths in country houses, street steps and other objects that are not subject to high loads. Products that can withstand heavy loads (high traffic, vehicle traffic) are produced only by vibration compaction - primarily due to the possibility of introducing crushed igneous rock into the concrete composition, which is responsible for the strength and durability of the structure as a whole.

Disadvantages of vibrocast tiles:

low density and frost resistance
low strength and durability
slippery/smooth surface of products

Advantages of vibrocast tiles:

low production cost (low product price)
huge variety of shapes
possibility of producing small volumes, “piece” orders
bright colors and shades with full coloring of products

Production of vibropressed paving slabs

Vibropressed tiles are manufactured in factories on special production lines. Unlike the production process of vibrocast tiles, a special press is also used to impart high strength and density to the product. Such paving slabs gain strength in steaming chambers, where they are exposed to high temperatures.

Such tiles are used for paving the surfaces of parking lots and entrances, where they will undergo heavy loads.

Shapes of paving slabs

The second classification basic method is the division of types of paving slabs by shape. We list the most common types:

square;
rectangle;
rhombus;
trapezoid;
puzzle of different shapes;
under brick;
waves;
coils;
honeycomb;
clover;
gzhelka;
scales;
feet or feet;
flowers;
sheets;
parquet;
web;
antique;
clouds;
fleece;
and many others.

You can find all the names and photos of paving slabs online. This way you can choose the most suitable option in a particular case.

It is important to note that the types of paving slabs are classic, that is, standard - those that have already been developed and thought out by specialists in factories, and can also look original and be made to order by professionals or made independently from pre-prepared forms.

The second method is quite interesting and has a number of significant advantages, the main one of which is the price component. That is, such products will not only look original, but also cost much less. This is due to the absence of the need for transportation and complex installation.

In this case, you can also use different materials both for the manufacture of the forms themselves and for the installation of types of paving slabs on site.

The only important recommendation is the need to carry out all work in the warm season, when the temperature should exceed 5 degrees Celsius. This will be needed to dry the products. At the same time, interesting designs and patterns can be made on the surface to suit the taste of the creator.

Production of hyperpressed tiles

Hyperpressed tiles are made using the semi-dry pressing method. It is also made from cement and marbled limestone with the addition of minerals and pigments.

Such production raw materials are placed in molds and subjected to a press with a pressure of up to 20 MPa. Then, the resulting products are exposed to high temperatures in steaming chambers with a special temperature regime. After which, the resulting products are dried in special rooms with a certain temperature and humidity regime. The process of such production is carefully regulated and must correspond to the developed technology in all its details. Hyper-pressed tiles are used not only for paving sidewalks, but also for arranging facades.

Paving stones. Production of paving slabs from natural stone

Paving slabs made from natural stone - paving stones - are the most expensive material for paving sidewalks, pedestrian and road surfaces, due to the fact that they have unique performance properties.

To make paving slabs from natural stone, rocks such as marble, granite, travertine, quartzite, and sandstone are used. Read more about natural stone in construction.

Products are made by cutting rocks using industrial machines. The sizes of the tiles can be very different, they are determined individually, upon request, and cutting is carried out into standard sizes. As a rule, the dimensions of the sides are: 100x100, 100x200, 200x200, 300x300 mm and the thickness of the product is 60-80 mm.

Paving stones differ in the way the edges are processed:

Sawn paving stones are a product with smooth edges that are sanded.

Split paving stones are paving stones that are made by chipping away pieces of rock, so that the edges of the stone take on a raw, natural or wild look.

Split-sawn paving stones, the stone is processed in such a way that the upper and lower surfaces of the paving stones are chipped, that is, they have the appearance of wild stone, and the edges of the product are made smooth.

Mold for paving slabs brick

If you want to show individuality, you can make tiles for garden paths, courtyards, and terraces yourself. Plastic molds for casting are available for sale. It is enough to buy a mold with a suitable pattern, make a mortar and make paving slabs.

For the solution you will need:

water;
cement;
sand;
plasticizer;
filler;
pigment.

The prepared solution is poured into the mold, leveled and left until completely dry. The result is tiles with a relief similar to brick or natural stone. They can be painted in different colors by adding dye to the solution. At the request of the manufacturer, they can be uniform or filled with stones and shells. Making tiles yourself opens up space for imagination and allows you to make paths with an individual design.

This is an economical solution. But it also has disadvantages:

production takes a long time;
if you accidentally disturb the proportions of the substances that make up the solution, the tiles will be less strong and durable than industrially produced products.

Therefore, if you value time and nerves, purchase it from a specialized company.

Production of clinker paving slabs

Clinker paving slabs are made like bricks from baked clay, which is why the common people call it clinker road bricks.

To produce clinker road bricks, a dry clay mixture is laid out and cleaned, then diluted with water. The wet clay mass is subjected to pressure through special extrusion holes to remove moisture and air particles. In this way, long rectangular blanks are formed, which are cut into products of the appropriate size. The finished product is dried for several days at temperatures up to 150° C, and fired in a tunnel kiln for two days.

Clinker paving slabs are used for paving sidewalks, driveways and parking lots, for lawns, and for water drainage. These tiles are produced in a variety of shapes and colors.

Manufacturing methods

The classification by type of paving slabs is based on the methods of its production and depends on the materials used:

concrete formats are produced using vibration casting and vibration pressing methods;
hyperpressed;
polymer sand;
clinker;
from natural stone;
with rubber base;
glowing.

Vibrating paving slabs

One of the most common types of paving slabs is vibrocast. It is made quite simply. For this, a set of tools is used: a concrete mixer, a vibrating table, and molds. The procedure itself includes the following steps:

Mixing concrete, which includes not only pure concrete, but also a cement component, as well as crushed stone, sand and water, a plasticizer and color pigment.
Pouring molds, which can also be made from different materials. For this reason, the number of castings per mold can vary greatly.
Vibrations to effectively remove air bubbles.
Settling for 2-3 days.
Removal of products and final drying on special rack structures.

The vibrocast type of paving slabs is considered the cheapest method in terms of manufacturing the final products. This does not require high-tech equipment, which allows you to perform all the procedures yourself. For this reason, it is used for summer cottages and areas for the construction of private dwellings, where there will be no serious loads.

In some cases, other components are added to the basic solution: granite or basalt chips, fiberglass, fiberglass. It is typical to use a reinforcement method to increase strength properties.

This type of paving slabs corresponds to a thickness not exceeding 6 cm. Other parameters are achieved by vibrocompression or hyperpressing methods.

Vibropressed

This production format is suitable exclusively for factory conditions. The tiles are made by vibration casting, so in addition to all the above tools from the previous method, you will also need other equipment.

It becomes a high-tech press, which adds density to the products and, accordingly, strength and durability. These paving slabs are suitable for locations where vehicles travel.

Hyper-pressed

This type of paving slab is created using semi-dry pressing. It is in many ways similar to the previous method. But the result is a product with improved wear resistance characteristics in relation to temperature changes, ultraviolet radiation, and mechanical stress.

The process goes like this:

The original solution is thoroughly mixed. Humidity does not exceed 10%.
Next, the resulting mixture is poured into molds and compressed using a press. The pressure is about 20 MPa.
After this, the resulting fragments fall under hot steam in special chambers. The temperature varies.
Drying for the final selection of the required strength indicators.

Polymer sand

This type of paving slabs is also manufactured in factories. The material is based on sand, consisting of large volumes of fine fractions. In addition to it, the composition includes polymer chips, additives and dyes.

The point of implementation is to heat the initial mixture to a temperature exceeding the possibility of potential melting of the polymer component. After this, the resulting suspension is mixed, then molding occurs under high pressure.

The resulting paving slabs are superior in properties to the concrete look. Let's list the positive aspects:

High frost resistance, resistance to moisture. Low moisture absorption.
High strength, ability to withstand significant loads.
Small weight indicators.
Chemical and corrosion resistance.
Long service life and durability.

Paving stones

Despite the fact that this type of paving slab is used quite often, it is rightfully considered one of the most expensive formats. It meets exceptional qualities and is suitable not only for use in an ordinary small country house, but also in high-status suburban areas.

In this case, different materials can be used: marble, granite, sandstone, quartzite, travertine. This requires competent sawing of natural stone. Moreover, here a standard dimensional line is most often assumed, indicated in cm:

10 by 10;
10 to 20;
20 by 20;
30 to 30.

Read also: How to lay porcelain tiles on the floor?

The thickness varies in the range of 6-8 cm.

In addition, it is worth noting the different options for processing edges:

sawn has smooth polished surfaces at the edges;
chipped corresponds to a rough and rusticated visual appearance;
chipped-sawn combines the two previous points, which is reminiscent of natural stone.

Clinker paving slabs

Has exceptional qualities. It is manufactured by firing clay. It is most similar to brick, but can have different color shades. It is often also called clinker brick. Creation of elements is based on the following actions:

Grinding dry clay mass, pressing through rollers, removing inclusions.
Add water and mix thoroughly.
Pressing dry mass and removing moisture and air.
Steel string cutting.
Drying for several days at high temperatures.
Firing in tunnel kilns for several days.

Rubber

Obviously, this type of paving slabs is used on children's and sports grounds, where it is necessary to avoid the effect of slipping with shoes during high physical activity.

It does not have many of the advantages that are characteristic of the previous types. But it allows you to use different color schemes and fulfills the above function to the fullest.

The production method involves heating the initial mass to high temperatures, mixing and molding. Let's list the pros and cons of this type:

Good shock absorption, anti-slip properties.
High degree of wear resistance, resistance to mechanical loads and temperature changes, ultraviolet radiation.
Maximum ease of installation, ease of repair work and dismantling if necessary.
Environmental safety for people and the environment.
No need for special care.

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Publication from DIY1 (@diy1.ru) May 12, 2021 at 5:09 PDT

Glowing tile

This type of paving slab attracts many thanks to numerous photos posted on the Internet. For this reason, it finds an original place in the country when there is not enough illumination in outdoor country conditions at night.

It gives landscape design special expressiveness and illuminates nearby areas.

To achieve this effect, two main methods are used. In the first case, the glow is achieved by placing LEDs inside housings made of epoxy resin. Moreover, the dimensions of such fragments coincide with the dimensions of the main elements of paving slabs.

Read also: Which adhesive for porcelain tiles is better?

The second option is implemented by applying luminescent paints. They collect solar energy during the daytime and then begin to glow as soon as it gets dark outside.