Do-it-yourself clinker tiles. Types of molds for the production of facade tiles and methods for its manufacture

Semi-dry pressing method

These technologies differ in the method of molding clay products.

In the first method, a slightly moistened starting material is pressed on special equipment, after which the molded product is placed in a kiln without pre-drying. The product obtained in this way has a low density, which significantly reduces its strength. But, this production technology makes it possible to obtain clinker with low thermal conductivity, which in many cases is valued more than resistance to mechanical stress.

It is this temperature that ensures the transition of the source material to stronger physical states. It should also be said that the main component of the cost of clinker tiles falls precisely on energy resources, the energy consumption for such firing is 4 times higher than the need for conventional processing of clay products.

09/11/2013 at 17:09

Materials and equipment
Production technology
wall decoration

Every owner of suburban real estate wants his house to be not only durable, warm and cozy, but also look attractive from the outside. There are many beautiful and durable materials for finishing the exterior walls of the house. These are facade tiles, vinyl, plastic, metal, polymer and insulating facade panels, fiber cement and porcelain stoneware slabs of various sizes, colors and textures. They can be attached to the walls both on self-tapping screws, and sit on a special glue. Facade panels, although the price is low, require certain skills and the involvement of specialists for their installation. The best solution for finishing the walls of the house will be facade tiles. Its installation on the wall does not require the involvement of specialists and specific construction equipment.

Today, construction stores offer various types of facade tiles for sale, which are distinguished by a wide variety of colors and unexpected design solutions. In these stores you can also buy plastic molds for them. The Forteza panel is distinguished by the most interesting execution and design. These products are clinker facade tiles made in the form of blocks. Despite the affordable prices, in order to cover the entire house with facade tiles, you will need a considerable amount, which not everyone has.

Modern technologies can significantly reduce the cost of the process of facing a private house.

Making tiles with your own hands is quite possible to establish at home, and this does not require special equipment for production.

Materials and equipment

To make tiles with your own hands, you do not need industrial-sized rooms. This work can be organized in a barn, garage or even outdoors under a canopy. Tiles can be made from a variety of materials. So, the following types of material can be the basis for manufacturing:

Concrete.
Starter putty.
Alabaster.
Gypsum.
Clay.

At home, it is preferable to make facade tiles using vibration casting technology. Clinker tiles, despite their obvious quality and strength, require firing. This requires special equipment, which is incompatible with savings.

The solution, which is poured into molds, may contain various fillers that give the finished product a certain look and properties.

As a filler solution can be used materials such as:

Sand.
Small shells.
plasticizers.
Dyes.
Sequins.
Glass crumb.

Given that no load will act on the tile, the main task in its production will be to get rid of air bubbles that can cause cracking and destruction in extreme cold.

Based on this, you will need the following tools and equipment for the production of facade tiles with your own hands:

vibrating table;
concrete mixer;
puncher with mixer;
trowel;
wide spatula;
trays for plastic molds;
an old bathtub or plastic water tank with a capacity of 100 liters;
form;
drying cabinet for placing molds.

If the owner of the house is not in a big hurry, then there is no need to purchase a concrete mixer to make the mortar, but to prepare the mortar in small portions of 10-12 liters in buckets using a perforator with a nozzle. The vibrating table is quite convenient equipment for the production of facade tiles. But given its cost, you can either make its analogue yourself, or carry out vibration manually.

Production technology

Work on the production of facade tiles should be carried out at a temperature of +15°C to +30°C. This temperature range contributes to the highest quality solidification of the solution. In order to comply with safety measures, it is necessary to use protective goggles and gloves. The production area must be well ventilated. First of all, forms are prepared. They are installed on a vibrating table or on the surface of a conventional table. The inner surface is lubricated with vegetable oil or liquid soap.

Business: production of clinker bricks and tiles

This will make it easier to separate the tile from the mold. After that, a solution is prepared for pouring into molds.

Solution preparation

Solution recipes may vary. In the case of making tiles from cement, the technology is as follows: 1 part of sand and 0.5 parts of water are poured into a concrete mixer (bucket) and mixed for 1 minute. Then 2 parts of cement and 1 part of water are added. After stirring for 2-3 minutes, 4 parts of sand and 0.5 parts of water are added. The solution is stirred. It should not be liquid, but resemble a modeling solution. When the solution has reached the desired consistency, the dye is added. After 1-2 minutes of stirring, the solution is ready.

Unfolding the mortar and hardening period

The next step is to lay out the solution in separate forms. This is done on a working vibrating table. The solution is gradually added with a trowel and distributed between the individual forms with a wide spatula. All the while, the form is vibrating. You can easily see how air bubbles come to the surface. When all individual forms are filled, they are generally leveled with a wide spatula. Along the way, the solution is removed along the sides of the mold. Then the form on the pallet is installed in the drying cabinet or on the rack. It is possible to provide holes for self-tapping screws in the forms.

The hardening period lasts 2 days. All this time forms do not disturb. Further, the form is lowered into a bath with warm water with a temperature of +40°С to +60°С for 2-3 minutes. After removing the mold from the water, the tiles are removed from it. This is done by hand or by tapping with a rubber mallet. The tile is ready. It will be suitable for fixing on the wall in 7-10 days.

wall decoration

Mounting facade tiles on the wall is not difficult. Vertical and horizontal elements of the frame are fastened to the wall with self-tapping screws. Tiles on the frame are fixed with clamps and self-tapping screws. Between the elements of the frame, you can lay slabs of mineral basalt wool. This will significantly warm the house. After that, successively screwing the kleimers to the frame with self-tapping screws, the cladding of the house is mounted from home-made facade tiles.

In the event of a breakdown of one or more tiles, such a facade will be easy to repair. To do this, you should have several dozen facade tiles in stock. You need to store them indoors or under a canopy.

Clinker tiles owe their unique qualities to the manufacturing technology, which makes it possible to obtain such material from ordinary clay. The technology for the production of clinker tiles was developed several centuries ago, and today there are practically no changes in it, although the equipment used has improved significantly.

What are clinker tiles made of?

In the manufacture of clinker tiles, natural material such as clay is used; natural dyes can be used to diversify the color scheme. It is possible to obtain a quality product only if clay is used, which has a minimum amount of impurities and is refractory. There are deposits of such material in a few countries, which is why a number of states can be distinguished on the territory of which enterprises for the production of high-quality clinker operate. These include Germany, the Netherlands, Poland, Spain and a number of other European countries.

Main clinker production technologies

In industrial production, two technologies for the manufacture of clinker tiles are used:

Semi-dry pressing method
Extrusion technology for the production of clinker tiles

These technologies differ in the method of molding clay products. In the first method, a slightly moistened starting material is pressed on special equipment, after which the molded product is placed in a kiln without pre-drying. The product obtained in this way has a low density, which significantly reduces its strength. But, this production technology makes it possible to obtain clinker with low thermal conductivity, which in many cases is valued more than resistance to mechanical stress.

Extrusion technology involves the use of a special device - an extruder. In fact, this is a large screw meat grinder through which wet plastic clay is passed. After grinding the material, molding is performed using a special, most often vacuum press. The resulting workpiece is subjected to pre-drying and only then sent to the kiln for firing. It is in this way that most clinker materials are produced; they are distinguished by a high density, which provides high strength, resistance to abrasion and other types of mechanical and chemical influences.

The main feature of production, which distinguishes clinker tiles, is the technology of firing at high temperatures. Ordinary clay products are exposed to temperatures of the order of 800-900 degrees. In clinker production, kilns are used, the operating temperature of which is 1100-1450 degrees.

It is this temperature that ensures the transition of the source material to stronger physical states.

Production and manufacturers of clinker tiles as a universal facing material

It should also be said that the main component of the cost of clinker tiles falls precisely on energy resources, the energy consumption for such firing is 4 times higher than the need for conventional processing of clay products.

Equipment for the production of clinker

The production of high-quality clinker tiles is impossible without the use of special equipment. To provide quality production line should include:

Extruder (with appropriate technology).
Equipment for molding and pressing. Various designs of pressing equipment are used, most often these are vacuum, belt, lever and rotary models.
Pre-dryers are now mostly electric, varying in power and load volume.
The main equipment for the production of clinker tiles is, of course, the kiln. Serious enterprises use the so-called tunnel kilns, the time when clinker was produced in small kilns using coal has already passed. Although such devices can be found in small private factories for the production of clinker products, but this is mostly an exception.

The tunnel kiln is a structure with a length of 150 meters or more. It is equipped with a heating source, which is an open fire. The blanks of clinker elements are placed in special trolleys, which move at low speed through the kiln. Due to this, there is a gradual heating, firing and cooling of the clay. Furnaces of this type operate in a continuous mode maintaining a constant temperature necessary for high-quality firing of products.

The production of clinker tiles requires significant energy costs, in addition, the delivery of material for production is also expensive due to the geography of high-quality clay deposits. All this has a significant impact on the pricing of the final product. But the increased price of clinker is more than offset by its performance, which makes its use quite popular in various areas of the construction industry.

09/11/2013 at 17:09

Making facade tiles with your own hands

Making facade tiles with your own hands is one of the options that are resorted to to save money. For this production you need:

Buy and prepare molds for tiles;
Purchase and assemble a vibrating table;
Knead the mixture for manufacturing;
Form a shape on the vibrating table;
For several days, keep the products directly in the molds;
Make formwork of finished tiles;
Use the finished tile for its intended purpose.

Do not forget that before pouring the mixture into the molds, they should be treated with an antiseptic or anti-stick compound.

In such conditions, you can reduce the cost of facing material, but at the same time, the facade tile itself is likely to be far from ideal.

Stages of production of facade tiles

career work

Works on the extraction of material, its transportation and storage.

Manufacturing process of clinker tiles

To increase elasticity and improve molding properties, the material is kept soaked and frozen in open air for about a year.

Treatment

In order for the mechanical processing of the material to be successful and of high quality, clay processing machines are used. They are needed for processing and isolating excess inclusions.

molding

For molding, the following methods are used: casting method, semi-dry pressing, plastic molding.

Drying

Drying is carried out so that the molded facing tiles do not crack during firing and give uniform shrinkage.

Burning

The final stage is the firing process, during which the structure of the facade tile and its technical properties are formed.

The video below shows how to make facade tiles with your own hands.

What is facade tile made of?

Both clay and concrete mixtures are used to create facing tiles. For concrete mixtures, the vibrocasting method is relevant. This method allows you to get concrete tiles with a low level of porosity. This technology makes it possible to use crushed stone, sand, plasticizers, cement, pigment and standard home-made equipment: a concrete mixer and a vibrating platform as raw materials.

Plastic molds are suitable for making artificial stone from gypsum and concrete. However, it should be remembered that it is impossible to make plastic molds that will absolutely repeat natural stone, since subsequently you will not be able to pull out a gypsum or concrete stone from a plastic mold.

Forms for a tile front (facing).

Concrete tiles: a brief excursion

Forms for the production of concrete tiles

We offer plastic facade tile molds at the manufacturer's price. In the manufacture of molds for facing tiles, we use ABS plastic 2 mm thick. Products made in ABS molds acquire an aesthetic appearance, strength and durability, which is especially important for outdoor decoration.

Our catalog contains the most popular forms for tiles: facade stone (artificial stone) of various types, brick-like tiles, wood, sandstone and other materials. We can also produce products according to your individual design, of any complexity and geometry, in any volume.

Our molds for the production of tiles withstand up to 200 concrete pours, while the manufactured products have an impeccable appearance and do not require additional external processing. Strong, wear-resistant, but light and convenient forms of facade tiles allow you to speed up the production process, and the resulting high-quality product is easier to sell and costs 40-60% more expensive.

If you want to buy facade tile shapes, but did not find the models you need in the catalog - contact us. We will advise you on our products and manufacture the products you need.

Tile mold No. 1
"Puzzle brick"
640x445x20 mm
4.32 pieces/m2
ABS 2.2 mm - 520 rubles / piece

Tile mold No. 2
Facade "Sandstone"
510x480x18 mm
4.1 pieces/m2
ABS 2.2 mm -450 rub/pc

Tile mold No. 3
"Brick smooth"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 4
"brick large"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 5
Facade "Old masonry"
500x500x18 mm
4 pcs/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 6
Facade "But"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 7
Facade "Chipped Stone"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 8
Facade "Chipped Brick"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 9
"Antique brick 1"
500x500x18 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 10
"Antic Brick 2"
500x500x20 mm
4 pieces/m2
ABS 2.2 mm - 450 rubles / piece

Tile mold No. 11
Facade "Smooth Stone"
500x250x16 mm
8 pieces/m2
ABS 2.2 mm - 210 rubles / piece

Tile mold No. 12
"Stone torn"
500x250x16 mm
8 pcs/m2
ABS 2.2 mm - 240 rubles / piece

Tile mold No. 13
Facade "Manhattan"
500x500x20 mm
4 pcs/m2
ABS 2.2 mm -450 rub/pc

Tile mold No. 14
"Stone Siding"
600x200x20/10 mm
8.3 pcs/m2
ABS 2.2 mm - 400 rubles / piece

Tile mold No. 15
"Brick smooth"
1000x500x18 mm
2 pcs/m2
ABS 2 mm - 650 rubles / piece

Tile mold No. 16
"Brick bassoon"
1000x500x20 mm
ABS 2 mm -650 rub/pc

Tile mold No. 17
"Smooth puzzle brick"
640x445x20 mm
4.32 pcs/m2
ABS 2.2 mm - 520 rubles / piece

Tile mold No. 18
"Three boards"
900x445x20 mm
2.2 pcs/m2
ABS 2.2 mm - 600 rubles / piece

Tile mold No. 19
"Block brick puzzle"
1125x500x40 mm
1.77 pcs/m2
ABS 2.2 mm - 820 rubles / piece

Tile mold No. 20
Molding for openings
500x90x50 mm
ABS 2.2 mm — 500 rub/comp

Tile mold No. 21
Wave
1000x500x20 mm
2 pcs/m2
ABS 2.2 mm - 650 rubles / piece

Tile mold No. 22
Clinker brick
1000x500x20 mm
2 pcs/m2
ABS 2.2 mm - 650 rubles / piece

Tile mold No. 23
Sandstone
1000x500x20 mm
2 pcs/m2
ABS 2.2 mm - 650 rubles / piece

Tile mold No. 24
Smooth
120x60x2 /4.5 cm
1.39 pcs/m2
ABS 2.2 mm - 850 rubles / piece

Tile mold No. 25
Smooth
60x30x2 cm
2.78 pcs/m2
ABS 2.2 mm - 450 rubles / piece

Form Pano No. 31
1020x340x25 mm
ABS plastic 2mm
Price: 680 rubles / piece

Form Pano No. 32
1020x340x25 mm
ABS plastic 2mm
Price: 680 rubles / piece

Technological features

When choosing ABS molds for facade tiles, pay attention to how ready-made facing panels will be joined. There are forms with a groove lock, which creates fewer problems when sealing joints, but adds difficulties when stripping and transporting tiles (more rejects). Rectangular ABS molds are easier to manufacture and practically not damaged during transportation, but require effort and time to seal the seams, since the joints have to be puttied to give the building an aesthetic appearance.

Ready-made facade panels are attached to the wall with glue and special anchors, for which some of our molds have markings for holes.

Do-it-yourself paving slab production at home

The production of paving slabs using vibrocasting technology is an interesting home business with little investment. This business idea has 2 main advantages: 1 good profitability, 2 an exciting production process itself (I want to work more and more).

You do not need self-motivation to exceed production targets. If you follow all the rules of technology, then the entire production process resembles a game. The tile is made so simply, quickly and beautifully that it is impossible to come off. The more you "play", the more you earn. Probably, this is an ideal business with elements of gamification.

It does not require large expenditures, while its profitability is above 100%.

Paving slabs are a building material that has a stable demand and the longest period of the season of active sales. After all, tiles are laid even at temperatures below zero. Moreover, this business has no industrial waste. Defective products can be recycled. This is a very important advantage.

Organization of home production of tiles

This business idea is optimized for a home business and is not difficult to implement with minimal investment. Stages of organizing a manufacturing business at home:

We do the vibrating table with our own hands (the diagram is shown below).
We also make polyurethane molds ourselves (detailed description in the business idea).
Concrete mixer 130l. better to buy (this is the most expensive equipment in this business).

cement grade A-Sh-400 (possible and higher quality, do not save on cement!);
screenings;
pigment dye;
plasticizer C-3 liquid (an analogue or substitute can be used, the main thing is quality);
water.

Additional tools:

bucket 10l.;
picking shovel;
trowel;
latex gloves.

In order for the whole production process to be like a game, we should prepare everything correctly without any compromises. Consider the basic stages of production:

Preparation of semi-dry colored concrete for vibrocasting.
Vibration molding of paving slabs and curbs in molds.
Daily exposure and stripping.

Mixture for the manufacture of paving slabs

Before starting work, moisten the walls of the concrete mixer with two buckets of water. After 2 minutes of moistening the walls of plain water, pour out all the water from the concrete mixer. This technique will allow us to better knead the semi-dry concrete mix. In addition, the concrete will not stick strongly to the walls of the mixer and it will be easy to clean after work.

Production steps in detail. The proportions of the components of the mixture for the manufacture of colored paving slabs and curbs.

Colored semi-dry concrete for vibrocasting. The recipe for the preparation of the composition of colored semi-dry concrete:

buckets of cement A-Sh-400;
buckets of water;
screening buckets;
200g. pigment dye;
plasticizer in accordance with the instructions for use indicated on the canister (different manufacturers of plasticizers are diluted with different concentrations).

First we prepare the pigment dye. It should be at least 2% of the volume in the mixture in order for the color to be of really high quality. We dilute it in a separate container with water 1:10 (for 200 ml of dye 2 liters of water). Mix thoroughly with a mixer. If the dye powder is poorly diluted with water, it will not only give a bad color, but also form lumps of shells in the structure of cast concrete products. They will have to be discarded and sent for processing.

When preparing semi-dry colored concrete, it is very important to strictly adhere to the ratio of all components and knead them thoroughly in a concrete mixer. If there is 30% more water than the norm, then the strength of the finished product will drop by 2 TIMES!

Too much dye negatively affects strength. In general, the presence of a dye negatively affects strength, so colored tiles should be made in 2 layers (the top layer with dye, and the bottom without).

Such a technique will not only increase the strength of thin concrete products, but will also reduce the cost of the dye by 2 TIMES! This is a significant savings because this component is the most expensive in this mixture. Such savings significantly affect the cost of paving slabs. Moreover, the color quality remains at the same level.

Add plasticizer for paving slabs C-3. Thanks to the plasticizer, at the micro level, concrete plasticity properties are improved, which are needed to create complex shapes. The quality of the plasticizer is easy to check if you make a hotel test composition and increase its dose by 10 times. Then plasticine is obtained from concrete. This is a clear example of what is happening at the micro level. But the plasticizer brings a few more benefits. Firstly, tiles made with a plasticizer will dry faster and are ready for demoulding in a day (without a plasticizer after 5 days). The plasticizer also gives strength to concrete products. It is important that it be of good quality.

Pour 2 buckets of water (20 liters) into the concrete mixer. We start the concrete mixer and add 3 of the same buckets of cement. Stir until a homogeneous suspension is formed. Then we add a pre-prepared dye. Next, add screenings - 4 buckets. Follow all these tips in order. After all, a semi-dry concrete mix is very difficult to knead with high quality. Semi-dry concrete for vibrocasting - ready!

Technology for the production of thin-walled concrete products

Technology of vibrocasting of paving slabs:

We lay out polyurethane molds on a vibrating table. Polyurethane is neutral to concrete, which cannot be said when talking about plastic. Polyurethane molds do not need to be washed (which will save the production cycle time by 2 TIMES!). It is more durable, and concrete products made in it acquire a glossy effect (with a very smooth surface). Polyurethane products can be poured with your own hands at home.
Semi-dry concrete is poured using a construction trowel. When all forming capacities are filled, the vibrating table joins. Under the influence of vibration, liquid is pushed out of semi-dry concrete and the concrete already acquires an elastic shape (it looks like a vein). When you look at this process, it seems as if the stone turns into water. Vibration should continue until a milky froth begins to form in the center of each mold. This takes about 3-4 minutes. Then we turn off the vibration and to make sure that everything is done correctly, we turn over one of the forms. The content must not fall out. This is how concrete with a low liquid content is compacted. Accordingly, the strength of such a concrete product is very high.
Paving slabs should be placed for curing and drying in a room protected from moisture and sun. In a day, she is ready for demoulding.

After stripping, we wipe the container and repeat this creative process in a second cycle.

DIY vibrating table

We manufacture a working vibrating table for the production of paving slabs and other thin-walled concrete products using vibrocasting technology. For this we need:

Metal sheet with a thickness of 5mm and dimensions of 1.5m. x 1m. for table top making.
Squares with a thickness of 3mm, side dimensions 5cm x 5cm.
Springs - 4 pcs. with an outer diameter of 5cm and an inner diameter of 4.5cm. The coil pitch is approximately the same as that of motorcycle shock absorber springs. But the height of the springs is not more than 8 cm.
Sections from the pipe - 4 pcs. to create bowls for springs. Their dimensions: inner diameter - 5.2 cm, height - 3-4 cm.
Electric emery with a power of 1 kW. with two white emery stones (stone diameter 10-15 cm, thickness 2-3 cm) on a through shaft and with protective covers.
Galvanized sheet (10cm x 50cm) and two large sunk bolts (diameter 10mm, length 10cm finely threaded step 1) to fasten the emery to the table.
Two counterweights (diameter 12 cm, thickness 2 cm). They should be fixed on the through shaft of the emery and closed with protective covers.
Toggle switch, cable and plug.

We assemble all the details into a whole device, as shown in the schematic drawing. 2 holes are drilled in the center of the worktop for mounting on the underside of the electric motor with counterweights. From the bottom, using a welding machine, cups are welded at four corners opposite the table legs. The lower part of the table is made of squares - the legs, which are interconnected for strength. Springs are fixed on the legs, on which cups with a table top are mounted.

Making and laying facade tiles with your own hands: step by step instructions

From the bottom side of the table, using a galvanized sheet (which plays the role of a clamp), an electric emery with a power of 1 kW is screwed. It also creates vibration due to the rotation of the weight with a displaced center. The farther from the center, the stronger the vibration.

A home-made vibrating table is several times cheaper than a factory one. But its capabilities are quite enough for home production.

When loading the table with molds with concrete, it is important not to overload it and take into account that the less weight is on the table, the higher the vibration. The level of vibration must be such that the concrete in the forms does not bounce off their walls.

Attention! The weight for vibration must be securely fixed on the emery shaft. Safety first!

Too much or too little vibration negatively affects product quality. There will be particularly low vibration in the center of a homemade table. While in places where springs are installed, vibration may be increased due to accumulation. Therefore, a homemade vibrating table should not be loaded on 100% of the surface. When laying out the forms, do not put them in the center and in the corners. Thus, the table will be loaded by approximately 70%, and the vibration in the molds will be uniform.

Most importantly, remember to follow safety precautions!

Do-it-yourself molds for paving slabs

Polyurethane molds have a number of advantages over plastic.

Polyurethane is absolutely neutral to concrete. This eliminates the need for plastic mold lubricant. But the main advantage of polyurethane molds is the elimination of a laborious process, such as washing each dish.

Ordinary plastic containers should be washed every time before vibrocasting. This takes up most of the work time. In home production, washing plastic molds will reduce productivity by 2 TIMES! Polyurethane forms need only be wiped with a slightly damp cloth.

To pour polyurethane molds yourself, you need:

collapsible box, which will play the role of formwork;
finished product made of concrete (tile, border, ebb, etc.);
release agent that is neutral to polyurethane;
components A and B for the preparation of the polyurethane itself.

A step-by-step description of cold casting polyurethane molds at home:

Preparation of a product that will act as a sample model for the mold. Thoroughly wipe and dry the sample model and formwork. After that, evenly apply a release agent with a brush to the surface of the model and the formwork. The release agent layer should be so thin that it is possible to transfer the structure of the decorative pattern to the form (for complex patterns, you can warm the release agent with a hairdryer after application to increase the efficiency of transferring the relief). Then let the grease dry for about 10 minutes.
Preparation of liquid polyurethane before mold casting. On an electronic laboratory scale, we weigh the components (polyol part A) and (isocyanate part B) for mixing in a ratio of 1:1. The temperature of the components should be room plus 21-24 degrees. When mixing, it is better to use the same volume of dishes with the components. For 2 to 4 minutes, mix with a mixer at medium speed, turning counterclockwise to prevent the formation of air bubbles.
Filling the formwork with liquid polyurethane. After mixing, we have no more than 10 minutes to fill the formwork with high quality while the “life time” of the compound (the process of transition from a liquid state to a gel state) continues. Tip: it is better to pour from one corner so that the polyurethane evenly covers the surface of the sample model like a volcanic lava flow until it is filled to the required level in the formwork.
Stripping. After casting, the product should not be disturbed throughout the day. And after 24 hours, stripping must be done very carefully so as not to damage the still fresh form. You can use the resulting form no earlier than after 4 days, so that the form gains its maximum strength and lasts several hundred shaping cycles.

Advantages of curly paving elements

Paving slabs are the most rational coverage for territories for a number of main reasons:

Mobility. Tiles can be removed and moved to another location. Can be replaced in parts if damaged during operation. For example, the appearance of greasy stains from car oil, etc.
Health safety. The tile does not emit a toxic smell in the heat like asphalt.
Strength. Plants do not break through tiles, as in asphalt. It does not crack under the influence of temperature changes like concrete pouring.
Aesthetics and beauty. Thanks to creative ideas, a whole technology has been created in the landscape design of FEM (shaped paving elements). From different colors and shapes of thin-walled concrete products, you can pave the whole masterpieces.
Affordable price per square meter.

There are many other minor advantages in FEM coating (absorption of water between joints, high-quality load distribution on the surface, etc.). The list can go on. But even this is enough to evaluate the benefits of this building material and its demand in the construction market in the long term.

Tiles are a versatile material that can be used to beautifully and reliably decorate a house, both inside and out. Someone orders tiles from special catalogs, paying for the services of specialists in the installation of products, and someone prefers to try himself in the field of not only a stacker, but also a master in the manufacture of tiles and decorative stone of the desired size, color and structure.

To obtain high-quality facade tiles or stone, you will need to use special forms. Again, there are two options here: buy pre-made molds or make your own. Let's take a difficult path and consider the process of making molds for tiles and artificial stone at home.

Features of molds for tiles and stone

For the manufacture of products is usually used ABS plastic, as well as a number of other materials, among which the most popular are silicone, PVC and polyurethane. It is these materials that allow as a result to obtain products with the desired degree of matte and glossy surface. Forms made of PVC and plastic are especially convenient because they do not require lubrication and steaming, since in the process of preparing products with their help, the concrete mixture does not stick.

An interesting material option for molds is polyurethane, which is especially strong and durable.. Polyurethane products can be used to cast more than a thousand slabs, the feature of which will be a perfect glossy surface.

Varieties of molded products

A wide range of products for casting facade tiles and stone opens up many possibilities for the implementation of unique design ideas in the direction of facade finishing. The most striking examples of products:

limestone ore;
figured slate;
dolomite;
marble ore, etc.

Pay attention to the fact that the laying of finished facade tiles or artificial stone requires certain calculations in order for the laying to turn out to be even and durable.

During the installation process, it will be necessary to use not only a level, but also such important materials as a rail and a plumb line.

Before moving on to laying tiles or stone, you will need to prepare:

buy go make molds for products with your own hands;
assemble or buy a ready-made vibrating table;
knead the composition for stone or facade tiles;
prepare the form on the vibrating table;
let the finished product brew in the form throughout the day;
carry out the formwork.

Finished products can be used immediately for finishing the facade, or they can be packed for further storage.

If you are not yet ready to make molds, then you can purchase finished products, the cost of which will vary depending on the material from which they are made.

How to make a tile with your own hands

The process of manufacturing facade tiles consists of several stages:

material extraction;
transporting it to a place for storage;
processing;
molding;
drying;
firing.

It all starts with quarry work - the extraction of material for the creation of products. Most often, clay is used, which is soaked and frozen at low temperatures for 10-12 months.

For high-quality processing of the prepared material, special machines are best suited, which will detect and process unwanted inclusions. At the molding stage, processing takes place in several ways: plastic molding, casting and semi-dry pressing. Finished products are dried to prevent shrinkage and cracks in the future, after which they are fired to form a finished facade tile.

In addition to clay, concrete mix is suitable for making tiles., from which it is easier to create products at home from do-it-yourself forms. In the process, the vibrocasting method is most often used to obtain slabs with low porosity on the surface as a result. By preparing a mixture of cement, sand and gravel, it can be colored with coloring pigments. As for the equipment necessary for the work, it will be enough to have a conventional concrete mixer and a vibrating platform.

Pay attention to the fact that plastic molds are suitable for making plaster and concrete products, but not clay. In addition, plastic is not a suitable material for the manufacture of molds intended for decorative stone, which ideally repeats the structure of natural stone.

Note that the manufacture of facade tiles today is an activity that everyone can master. The material is easy to use and allows you to create a finish that protects the facade and gives it a special texture. Molds for casting products are distinguished by their plasticity and practicality, allowing you to make materials of the desired color, texture, visually as close as possible to natural ones, with your own hands.

Production of molded products for decorative stone

Forms for artificial stone, as well as for tiles, can be made by hand or bought ready-made complete with materials for making products.

The most convenient to use are rubber, silicone and polyurethane forms, from which the stone is easiest and fastest to remove after the mass has solidified.

Given that the cost of ready-made forms is high, it makes sense to consider the possibility of making them at home.

The dependence of the price of silicone and polyurethane on the brand

The best option is to make a mold from polyurethane. Packing a material weighing 7 kg will cost no more than three thousand rubles, while from it it will be possible to make several forms of the sizes you need at once. If you decide to use silicone, then it is best to select a European-made acetic-based material.

To make it easier to remove finished products from the mold, it is useful to use matrix separator, which is easy to make from gum turpentine, beeswax and paraffin. To prepare the mass, wax with paraffin is melted in a water bath, adding turpentine at the end. Lubricate the sides of the mold and the surface of the stone with the mixture.

The instructions for making a polyurethane or silicone mold are as follows:

Choose a few stones that you think are suitable for the role of samples.
Lay them out on a piece of chipboard or fiberboard, face down, a few inches apart.
Treat the smooth side of the stones with silicone and press firmly into the surface.
Treat the contours of the stones with sealant so that air does not get under them. Silicone for aquariums is suitable for pouring, which will help to avoid leaks.
Let the sealant dry for several hours.
Prepare the formwork at a distance of a few centimeters from the stone.
Seal the edges and corners of the formwork with silicone to prevent leakage of polyurethane.
Allow the mass to dry (at least 12 hours).
Lubricate the formwork and samples with the wax mixture prepared earlier and let dry for two hours.
Prepare the polyurethane mixture.
Fill the matrix with silicone or polyurethane. Pour polyurethane in a thin stream, silicone with a brush dipped in soapy mass.
Dismantle the formwork in a day and remove the stone models from the mold.
Dry the finished products for two weeks.

Tiles are a versatile material that can be used for cladding, bringing beauty to your home and ensuring a long service life.

Often, when it comes to tiles, they are used to ordering a product from manufacturing companies or buying it in hardware stores.

However, there is a way to make tiles yourself, while it is possible to create your own kind of tile.

To do this, you just need to make a form and a quality solution.

It is better to consider this issue in detail in order to make high quality tiles.

It is mainly used in the event that it is not possible to carry out facing work using bricks. For a tile, the bearing function is not typical, and when a wall is erected, such material is not involved in the installation. Facing is carried out after the wall has been erected.

In thickness basically the front tile is issued 14 mm. Given this thickness parameter, the method of wall cladding using this material can be called gluing. For reliable fastening with the wall surface, a special adhesive composition is applied to the tile. Using tiles, you can clad not only the outside of the building, but also the inside.

From the variety of tiles, the following can be distinguished:

. It has a high level of density, has a wide variety of geometric shapes in which it is produced.
. It has become quite popular in recent years. The shape in which it can often be seen is a square or rectangle. It has a fairly large size, thanks to which it is not only profitable to use, but also convenient, since installation with the help is simple and does not take much time.
Polymer sand. The main purpose of this type of material is decoration. Due to this type of tiled material, a wide variety of design ideas can be realized.

Less popular ones are also distinguished, such as:

Production process

Before embarking on the process of creating tiles for facade cladding, it is best to have an idea of what the process is.

The temperature regime at which it is necessary to carry out all manufacturing work should be in the range from plus 15 to plus 30 degrees Celsius. This temperature regime must be observed in order to ensure the highest quality process of solidification of the solution. In addition, the work requires the use of protective clothing and devices, be sure to wear goggles for protection and gloves.

The room in which the work is carried out must be constantly ventilated. The first thing that the process of creating tiles requires is the manufacture of molds. They are installed on a vibrating table or on any flat hard surface.

They are lubricated with a small amount of vegetable oil or liquid soap. This allows you to easily separate the finished product from the mold in the future.. A solution made according to a special recipe is poured into molds and left for the required period of time until the moment of complete hardening.

Forms for facade tiles

One of the highlights in the process of creating a tile or artificial stone for is the shape. This fixture is made from ABS plastic.

This material is the most widely used among others, but silicone, polyvinyl chloride or polyurethane can be used for such purposes. These materials are able to provide a quality result that will have the desired degree of haze or be glossy on the surface.

As for the molds made of PVC or plastic, they are convenient to use because they do not need lubrication and steaming, since the mixture that is poured into them from concrete is not able to stick.

A good option with regards to the material from which molds can be made is polyurethane. It has good strength and durability. If the form is made of polyurethane, then it can be used for quite a long time, having made 1000 or more tiles with it. In addition, this form gives the tile a glossy perfect surface:

There is a wide variety of types of shapes that are used to create facade tiles.

Among the main ones are:

limestone ore;
marble;
faceted limestone;
cliff;
dolomite.

By creating tiles on your own, you can make a shape that does not look like any of those listed. Thus, the lined facade of the building will be one and only of its kind.

Manufacturing process

The whole process that you need to complete in order to create a facade tile with your own hands can be divided into several stages.

Such as:

creating forms;
solution preparation;
final stage;
direct receipt of the finished product.

Making molds from polyurethane

Initially, you need to decide on the appearance of the tile that needs to be made. In addition, you need to determine all the parameters of its dimensions. . It is very important to correctly make its front surface. For simplicity, you can use ready-made products made of natural stone, which must be imitated.

In order to make a mold, you need to use a two-component polyurethane casting compound. Such solutions have the necessary level of performance characteristics that remain with the finished product.

The whole process can be represented as follows:

For the base, you can use a piece of plexiglass, the size of which is slightly larger than the area of \u200b\u200bthe stone. It should be applied face up.
After that, it is necessary to measure the level at which the sample exceeds the stone and draw a contour for the construction of future formwork. The height of the formwork should exceed the sample by 2 cm.
The stone, removed from the base, using silicone sealant, is attached to the plexiglass, adhering to the applied contour on the formwork.
After the mortar has been poured into the formwork for the form, it is necessary to wait a while for solidification. It often takes 24 hours for such a process.

Solution

The solutions that are used to make tiles with your own hands are very diverse.

In this case, an example of the most popular solution based on cement is given.:

it is necessary to pour 1 part of sand and 0.5 of water into a container suitable for mixing the solution. It is necessary to mix the composition for 1 minute;
after that, cement (2 parts) and water (1 part) must be added to the resulting mass. Mix everything thoroughly;

NOTE!

The consistency of the solution after mixing should be similar to the solution intended for modeling. It is impossible for the mass to be liquid.

when the desired consistency has been reached, a coloring pigment can be added. After stirring the composition for 2 minutes, we can assume that the solution for facade tiles is ready.

Unfolding into forms

The process of laying out the prepared solutions according to the forms must be carried out on a vibrating table, which must be turned on during the process. It is necessary to fill the forms with the composition in portions, for this you can use a trowel or a wide spatula.

The composition during the layout process must be subjected to vibration. This allows air to be removed from the mass.

After the mass has been spread over all the forms, it is necessary to additionally level the surface using a wide spatula. It is also necessary to remove the composition that got on the sides of the molds.

The last thing to do at this stage is to remove the filled containers with the composition in a drying cabinet or put them on a rack.

The duration of the period that is necessary for the tile to harden is two days. During this time, molds with a solution should not be touched..

After the specified period, you can begin to extract the finished tile from the molds. To do this, they are first dipped in water, the temperature of which is 40-60 degrees Celsius and left for 2-3 minutes. After the tile is removed from the water, the mold should separate well.

To facilitate the process, you can use a rubber mallet and lightly tap it on the mold surface..

Conclusion

Making facade tiles with your own hands is a rather exciting process. In addition to the fact that it is possible to make the tiles you like most, which will imitate artificial stone or brick, you can significantly save money on repairs.

You can start the process of finishing the walls using hand-made tiles after 7-10 days. The quality of do-it-yourself tile material differs little from that offered on the construction market.

In contact with

To decorate the house outside, facade tiles are often used. Various materials are used in its manufacture. Each product type has unique properties.

Fake diamond

Types of facade tiles

This decor is used in the cladding of buildings outside. That is why a number of specific requirements are imposed on it:

Strength. Immunity to mechanical damage, scratches and point impacts.
Wear resistance. Should remain in its original form for a long time, resist abrasion and deterioration, including mold.
Waterproof. Minimize the number of pores through which moisture penetrates.
Frost resistance. A must for outdoor tiles of any type.
Light resistance. No negative reaction to ultraviolet radiation, including the preservation of the original color.

And, of course, when making facade tiles with your own hands, keep in mind that it must guarantee the durability of the coating.

One of the cladding options is the manufacture of artificial stone from concrete.

The following types of tiles are used in the decoration of building facades:

Ceramic granite. This is a combination of clay rocks and granite chips, which provides maximum strength and imitation of natural surfaces.
Clinker. Expensive, but high-quality material obtained from shale clay by firing.
Terracotta. Made from porous kaolin clay. Heat-resistant, but not strong enough.
Concrete. It is made from a mixture of raw materials for cement and additional additives that improve its properties.

Necessary tools and equipment

A huge plus for making cladding with your own hands is the ability to develop unique designs. Experiment with the composition of raw materials, but do not violate the basic proportions and product requirements.

The easiest way is to make concrete tiles. To make it by vibrocasting, you only need a set of molds and a vibrating table. Matrices are made of wood, plastic, plywood, but the best option is polyurethane. Such templates allow you to convey the texture of the tile in the smallest detail and imitate natural stone. The vibrating table can be made independently from a metal frame, a sheet for the countertop, springs and a motor from a washing machine.

The easiest way to create concrete tiles is vibration casting, you only need raw materials, a vibrating table and molds for pouring

The second way is vibrocompression. This setting is needed for all tile options, as it allows you to maximize the density of the raw material without using a lot of water.

In order for porcelain stoneware, terracotta and clinker to reach the finished state, you need a kiln. Each material requires compliance with a certain temperature regime from 1000 to 1300 degrees.

Manufacturing methods

Consider two options for the production of tiles. The first is made of concrete, which is much more accessible to most people. You will need white Portland cement, sand and small gravel, as well as lime or another plasticizer. Be sure to use modifiers to increase frost resistance and water repellency.

The principle of making concrete tiles by vibratory casting is as follows: the mass is poured into a mold, then the blanks are placed on the platform of the vibrating table and the equipment is turned on. After removing the air and tamping, the molds are dried.

To color concrete tiles at the mixing stage, pigment is poured into the liquid mass. More economical is the option of applying paint to the inside of the form.

Use of polyurethane matrices

Clinker tiles are made a little differently. The clay mass is mixed with modifiers, then it is poured into a vibropressing machine, which forms blanks by compressing the mass under pressure and vibrating it. After that, the clay is allowed to dry and sent to the kiln to fire. For clinker and porcelain stoneware, the temperature is adjusted to 1300 degrees, for terracotta - up to 1000.

Laying tiles

Align the surface of the walls of the building in advance. In addition, it is best to conduct insulation and treatment from the fungus.

Laying tiles is carried out on a special adhesive that is resistant to atmospheric phenomena and temperature fluctuations. Use compounds that are not afraid of moisture, but this is not necessary, in contrast to the frost resistance criterion. Since the weight of the finish is significant, the adhesion of the mortar to the surface must be appropriate.

Stages of installation of homemade facade tiles

Laying is carried out under favorable weather conditions. The temperature should be between 5-25 degrees Celsius. In frost, the properties of the glue deteriorate, it freezes, and in heat, moisture evaporates too quickly.

Apply the solution both on the wall and on the tile itself. With a complex layout scheme, it is better to use the second option. Remove the adhesive protruding in the seams after the final fixation of the material. The gaps are filled with water-resistant fugues, for example, cement-latex. It is best to use a syringe so as not to stain the tile itself. After drying, the facades are treated with a water-repellent liquid, for example, a water repellent. This applies in particular to concrete and clinker samples. After such work, the lining will last you much longer.

Building or renovating a house is a rather exhausting process in every sense, but at the same time instructive and exciting. When the construction is already coming to an end, one of the last steps is the laying of facade tiles. Such a finishing touch not only aesthetically transforms the appearance of the building, but also provides insulation of facades, while extending their service life.

Nowadays, tiling facades is a fairly popular activity, due to which it is not easy for beginners in this matter to make a choice or carry out the process itself. Let's figure out what the laying is, what kind of tiles there are, and also consider the features of the work and give some recommendations and tips, reinforcing the material covered with instructive videos.

The concept of facade tiles and factors affecting its price

Facade tiles are a building material, thanks to which the building acquires an attractive and individual look, but at the same time it is an indispensable means of isolating the house from external destructive atmospheric phenomena and a heat insulator.

In general, facade tiles are made of natural and artificial stone. If in the first case the entire installation will require considerable costs, but this will be compensated by the resulting beauty and practicality, then in the second case it is a good analogue of natural material at a more attractive price.

The cost of this material depends on the following factors:

production raw materials;
manufacturing technology;
sizes and shapes;
color and type of decor;
manufacturer.

In order to save money, many people resort to making such tiles with their own hands. The desired results can be achieved if you are familiar with the manufacturing process itself, which is presented in video 1. The video will help not only learn how to make it yourself, but also understand the steps of the procedure.

Types: pros and cons

Consider the classification of facade tiles, noting the advantages and disadvantages of each type.

This facade tile is produced by mixing several types of clay, dyes, sand, feldspar and various mineral additives, after which the product is fired at temperatures up to 1300°C. Variety: plain, interspersed and imitation of natural stone. Pros: water resistance, frost resistance, wear resistance, and it is also an environmentally friendly material of different sizes. Cons: Laying is complicated due to the large weight of the material.

Concrete

Manufactured from Portland cement, sand, lightweight filler and additives that give it strength and frost resistance. Due to vibrocompression, facade tiles are obtained, which are subsequently dried in ovens and coated with sealants. Pros: a variety of surface textures, a wide range of colors, light weight, low cost and easy installation. Cons: lower level of frost resistance, compared with other species, large size, complexity of care.

Terracotta

Produced from kaolin clay at a temperature of 1000°C and has a porous structure. Subspecies: smooth, coarse-grained and polished; black, dark brown and light brown. Pros: no dyes, imitation of natural stone, easy installation due to low weight, temperature-resistant, does not fade in the sun, provides climate control to the premises, does not require maintenance. Cons: mechanical stability is lower compared to other types.

Clinker

It is made from shale clays at a temperature of 1300°C. The diversity of the material is ensured by the addition of dyes during the production process. Outwardly similar to a brick. Pros: there is no calcium carbonate and salts in the composition, low water absorption, long service life, frost resistance, a variety of colors and textures, does not fade in the sun, is resistant to mold and fungus, does not require special care. Cons: high price.

Advantages and disadvantages of styling

Before you start laying facade tiles, you are advised to familiarize yourself with a number of advantages and disadvantages of this process.

Advantages that laying gives the building:

maintainability;
resistance to mechanical damage;
resistance to external atmospheric phenomena;
facade insulation;
variety of appearance;
possible reuse.

Flaws:

the need to prepare the walls of the building;
the need for mesh reinforcement;
high price of work and material;
physical wear of the glue used;
laboriousness.

The nuances of the facade finishing process

The process of facing a building is far from an easy task that requires certain skills and knowledge. The technology of laying facade tiles can be simplified by taking into account some of the nuances, which allows you to achieve the desired result.

Experts recommend that tiles be laid in the warm season, while the temperature should not, if possible, go beyond 5-25 ° C. When the specified temperature limit is increased, it is necessary that the warm tile on the back side is slightly moistened. When working in bad weather, discoloration may occur.

Before laying the building material, the walls must be prepared, in particular, leveled, which involves plastering. For this procedure, professionals advise using a reinforcing mesh.

In order to achieve the planned results, we suggest that you familiarize yourself with the following video 2. This material will briefly and clearly outline the essence of the cladding work using the example of a separate section. The video colorfully describes the whole procedure.

Do-it-yourself exterior decoration of the walls of the house can be carried out using different laying techniques. If the specialists carry out, the price of the work will be quite high, therefore, if you try, you can create an individual facade yourself according to your requirements. A little desire and diligence - and the result will surely please you. The video will also show us how houses can be transformed with tiles.