Form for the production of concrete rings. How is the amount of water calculated? List of necessary equipment

I was forced by circumstances. In the hot summer of 2010 many summer residents faced the problem of water supply.

Uninterrupted water supply wells dried up.

Most owners of suburban and suburban areas use wells with reinforced concrete rings with an internal diameter of 1000 mm and a height of 900 mm.

It seems to deepen the well - not a problem, but ...

Seduce clamped the soil of the well is not possible, digging a well from all sides is unrealistic ...

The first thing that comes to mind is that it's easier to dig out a new one, but the price of a ring in 2000 rubles instantly jumped to 2300-2400 rubles, in the presence there, the queue is painted for 2-3 months ahead. And you want to drink and you need watering a garden. If you move a little gyrus and get off the couch near the TV, then this problem can be solved in a few days, save for someone a significant part family budget, and some and stir up the profitable business. It goes without saying that the outer diameter of the rings to deepen the existing well must be less than 1000 mm. I took the outer diameter of 840 mm, the inner 700 mm and the height of the rings 600 mm. Concrete for such a ring will require 100 liters, ie, about 180 kg, for the preparation of which you need 50 kg of cement (180-190 rubles), sand 130 kg (45-50 rubles), a bucket of water and about 10 kg of wire (let it be 100 rubles, but I'll find or steal 4-6 mm). The cost is not more than 340 rubles. for 0.6 meters of linear future wells. And how much would a standard ring cost 2,400 rubles, if its height was not 900 mm, but 600 mm? 2400 rub. : 900 mm x 600 mm = 1600 rubles. We save 1260 rubles. on each ring. I get off the couch and go to the garage (he's a workshop and a warehouse for illiquid goods).

To be immediately clear, I show the finished form for well rings  self-made.

This I had to do. Generally make a formwork for the rings with your own hands  not difficult. How to make a shape for the rings  I came up with it quickly.

If you know how to use metal scissors, a Bulgarian and a little electric welding, flag you in your hands and let the shabashniks break off.

I cut with a scissors on metal from a sheet steel of 1,8 mm thick two rings internal diameter 840 mm, external 900-950 mm. The outer diameter is unprincipled - this will be the ribs of rigidity for the outer part of the formwork. Scissors shear normally, if you lengthen the handle. A sheet of metal with a width of 600 mm rolls into the "tube", on the top and bottom - rings, I weld, cut the resulting gizmo into two halves with a bulgarian, I strengthen the places of the cut with corner steel with bolt holes for assembly and disassembly.

It's harder with a freckle ... you need to think of something to prevent it from being squeezed by concrete after pouring, and it would be possible to take it out freely. Therefore, before casting, its diameter should be equal to the design diameter, i.e. 700 mm, and after pouring - to decrease by 15-25 mm.

I decided to solve this problem by destroying two old car jacks, making of them a device for compressing the expansion to four sides.

It's easier to show than to explain:

I collect an inner "barrel" of two round details with a diameter of 700 mm (type, bottom and cover), and the wall of the keg, again of sheet steel with a width of 600 mm. The sheet again rolls into the tube, so that it does not roll out - I pull the cable with the winch, I weld the bottom and the lid. In the lid and bottom of the finished barrel, I cut out the square holes (I can not cut out the round bulgaria), I install inside the perversion, which turned out of the jacks, cut into 4 parts, strengthening the places of the cut with a corner.

I check whether the compression-decompression mechanism works:

Works fine.

I'll digress a bit: if you make thin metal casings, for example, from galvanized steel with a thickness of 0.55 to 0.8 mm, a width of 600 mm and a diameter of 700 and 840 mm, then with their help you can not wait for concrete filled in homemade, and immediately after vibration of the concrete mixture the formwork should be removed. Thus, it will be possible to cast in a day not one ring, but as much as the pairs of shells you will procure. Even thin metal shells will not allow the concrete mixture to fray after the formwork is removed.

In this photo, pay attention to the bolts. They, among other things, play the role of limiting the expansion.

Now you know how to make a formwork for rings. Then we knit the reinforcing cage. Its design can be any, the main thing is that the distance between the rods is no more than 200 mm in height and 300 in circumference. The diameter is 770 mm. Loops do not forget to release.

At me such it has turned out:

We attract free labor in the person of relatives to mix concrete mix in old tub. I could not catch relatives, but there is a concrete mixer.

Fill the finished mixture in the self-made formwork for the rings, vibrate the piece of reinforcement and go to drink beer on the couch under the TV until the next day. Overnight concrete will grasp, and it will be possible to shoot the homemade form.

The outer part is easily removed. The inner part must be removed carefully, so as not to damage the ring walls. Do it better together or build a lifting mechanism like a crane.

Rings in natural conditions of strength set is better given for two weeks to stand, then you can load, transport, cant, if the cement is not saved, of course ...

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Construction of elements of formwork

In order to pour concrete into the mold, it is necessary to make the formwork. What should the formwork look like for this concrete? Since for the well we need an annular shape, the formwork is prepared in the form of two collapsible rings made of wood or metal, which are concentrically installed into each other. Specialists advise using metal barrels, pipes or air ducts of the required diameter for these purposes. In any case, the use of wood for the manufacture of formwork for reinforced concrete rings, for obvious reasons, is very problematic, although it is not altogether excluded.

If two cylinders of the required size are available, then you can start making the formwork. Outside the large cylinder, two longitudinal lines are drawn, which will mark it vertically in two equal parts. Along both lines, two ordinary door awnings are fixed in such a way that their flaps are on both sides of the marking, and the bend of the canopy is aligned with the line itself. At the same time, on the inside of the cylinder, a similar marking is made, along which the cylinder is cut from the inside by a bullet into two parts. Doing this work, try not to damage the canopies. Then you need to carefully disassemble the hinged joints of the canopies only on one side, cutting off the hood fixing spindles. As a result, a drop-down form is obtained, the mobility of the sides of which should be developed, after which the cylinder flaps are reinstalled again with the same or other fixatives. Subsequently, this will facilitate the work, when the concrete mixture is solidified, the formwork becomes unnecessary and can be removed.

Then the inner cylinder of the formwork is processed. From the inside of the cylinder two longitudinal markings are applied at a distance equal to 1/3 of the circle, one from the other. In the same place, on the inside, sheds are installed according to a similar scheme. The cylinder is cut from the outside, the hinge joints are dismantled along one of the lines, after which they are reassembled. In the finished form, the inner cylinder will be 5-10 cm above the outer cylinder, while the outer form of the formwork for concrete rings  It should easily open outwards and be fixed by spindles, and the inner cylinder - it is easy to open inside. In the process of manufacturing formwork you will need:

• metal cylinders;
• door (window) canopies;
• fasteners for installation of awnings;
• metal dies;
• a Bulgarian and a thin cut-off wheel.

Pour concrete mixture into mold

After that, proceed directly to the manufacture of reinforced concrete rings for the well with your own hands. The ambient air temperature when pouring concrete mixture should not be below 8 ° C. Do not forget that a high temperature is needed to quickly set strength in the early days, afterwards the temperature above 22 ° C will only worsen the quality of the concrete. The formwork should be on a flat surface, in the space between the two forms a reinforcing mesh is placed. To ensure that the cylinders do not move when pouring concrete mix, you can fix them with wooden spacers. Pouring occurs in layers of 15-20 cm, each time the mixture is thoroughly rammed. After the entire form is filled, the end of the future reinforced concrete ring for the well should be leveled. After three or four days, the formwork can be removed. The inner form is removed first, the canopies are freed from the spindles, the smaller part of the cylinder folds in and is easily removed from the ring. The outer cylinder is also removed, but with opening to the outside.

Fresh concrete should be periodically moistened to increase its strength. As a rule, for complete hardening of the concrete, 28 days are required. After this period, the reinforced concrete structure is considered ready. A finished ring can be used to construct a well.

Autonomous source drinking water  on a suburban area is a good alternative to central water supply. Very often, a well or a well is the only way to get water not only for eating, but also for watering the garden and garden. Despite the fact that wells are gaining increasing popularity, traditional wells are not worth dumping.

The simplest version of such a source is from concrete rings. Forms for the production of well rings can be purchased ready or made by hand. The article will tell in detail how to do it yourself.

General information

The classical form for the well rings is reminiscent of a cylinder, but there are also rectangular variants. It should be noted that they can also be with and without lock.

Traditional products have an end flat. If there is a lock, then they are endowed with docking ends. According to experts, in this case, the rings have better tightness, and the whole system is reliable.

The standard sizes of the base rings are divided into groups:

• great  - weight 1.5 t, inner diameter 2 m;
• the average  - weight 1 ton, height - 900 mm, inner diameter - 1.5 m;
• small  - weight 600 kg, height 900 mm, wall thickness - 160 mm, internal diameter - 1 m.

In addition to the standard well rings, there are also output of wall gates that differ in height and are used to create a sector of the well projecting above the surface of the site. They have a lower height than standard options. An important element of the construction of the well is, included in the kit and having a certain diameter.

Annually, the production of reinforced concrete rings is getting better due to the constant introduction of new developments. For example, when laying metal fittings, laser cutting is now used. Innovations contribute to the production of high-quality and reliable products. Due to the simplification of production, the final cost of the reinforced concrete rings is steadily decreasing.

We make rings for a well from reinforced concrete

In this case it is necessary to purchase or manufacture, or maybe rent out special forms of well rings. For the creation of the outer and inner diameters, metal formwork is used.

In the free space between the formwork sheets, wire or reinforcing wire mesh is installed, and then the entire structure is poured with concrete solution. It is best to compact the mold with a vibrator, if at home it is not, then it is carefully made with a wooden bar.

You must remove air from the mixture so that the concrete is compressed as best as possible. If everything is done correctly, as a result you will get a very strong product that can withstand heavy loads and perform its function efficiently enough.

When self-manufacturing  products, often install special travel braces. Special production locks are often installed at manufacturing plants. This allows the design to have a dense and reliable fixation of the trunk, which eliminates the displacement of its elements.

Technology

Tip: do not rush, the main thing is to carefully follow all the steps, then you will get the expected result.

Below is a step-by-step instruction.

At first glance, it is complex, but in the process of making you will understand that everything is simpler than it seems.

1. To create a shape, pick up 2 barrels of metal, which will match it, usually their price is waste. The fact that they will be technological vyshtampovka, the manufacturing process will not affect. If the barrels are not found, you can take air ducts or pipes of the desired diameter.
     Collect the formwork cylinders and connect the individual sheets together. A good result is observed for formwork, created from plastic cylinders.
2. Make two longitudinal markings on the outer side of the outer barrel of the future shape, which will divide it vertically into two equal halves.
3. Take a pair of door awnings and place them on the markings so that their bends are on top and along the markings, and the leaflets are located at the edges of the line. Attach the canopies with welding or rivets.
4. Copy the markup onto the inner ring of the formwork. In the place of mounting canopies with only one side, cut off each lower hinge-fixing bracket.

Tip: Be careful not to damage the outer ring during operation.

1. Remove the cut spindles and open the resulting shape. Lock shutters will be cut off spindles or others, but suitable for the diameter.

1. Prepare the inside. Use a prepared form or a metal barrel for this. Put two marking lines inside, which are placed one from another on a 1/3 segment of the circumference. Take care that the cylinder is not divided vertically into equal parts, the difference between the width of one part and the other should be almost 2 times more. Install the canopies on the inner formwork, as well as outside.
2. Copy the layout from the inside to the outside. Then cut the cylinder neatly along the lines, so as not to disturb the inner awnings. Cut the spindles, pull them out and develop the resulting shape. Adjust the comparability of the parties.
     Ensure that in the assembled form the inner formwork is 50-100 mm higher than the outer one. The outer part of the structure should be easily opened, closed and fixed. Internal - it is easy to open inwards.

After releasing the ring, first remove the inner shape. Then the canopies are freed from the spindles, gather the smaller part of the mold inward and pull it out of the fresh product, remove the outer one by opening it to the outside. This form for the production of well rings can be used many times.

Conclusion

It is not difficult to make a mold for a well of a concrete ring. To do this, you need to pick up the corresponding metal sheets and collect them in a certain order. In the video in this article you will find additional information on this topic.

Shape of the well ring  It is used for making wall wells of ferro-concrete rings GOST 8020-90  and series 3.900.1-14  method of vibroforming, that is, laying a concrete mixture in a vibroform with the subsequent action of vibration and stripping of finished reinforced concrete products immediately after molding. With this technology it is possible to produce rings of wells of almost any size.

According to the experience of 6-year work, the most common vibroforms COP10.9  and KS15.9  , slightly less in demand KC20.9  and КС7.9. Forms such as KS12.9 and vibroforms for rings with a thickened wall are made to order.

The technology used ensures high productivity (up to 30 products per shift using one mold), but it requires the production of a concrete mix at the molding site with a clear control of the moisture content of the hard concrete mix. In most production conditions, the moisture content is monitored visually, by the nature of the mixing of the concrete mix in the concrete mixer. It is quite possible to transport a concrete mixture in a tub or dump truck from closely located concrete assemblies, but the volume of concrete should not exceed the hourly production requirement.

Advantages of our vibroforms for well rings:

1. Wall thickness of the mold  allows you to maintain the accuracy of geometric dimensions throughout the life of products

2. Number of vibrators, installed on the vibroform, determined and reconciled for 5 years of operation vibroform.

At the request of the customer, the number of vibrators installed on the mold can be changed.

3. Power of vibrators, installed on the mold affects the duration of the vibration of the concrete. The higher the specific power factor, the faster the consolidation of concrete. We use the IV-98 electric-vibrator with a power of 0.9 kW. Note that, despite the presence on the market of vibroforms with vibrators IV-99 in the same quantities (for example the form KS15.9 with 2 vibrators) and their relative cheapness, preference should be given to more power-hungry forms: electricity consumption increases insignificantly. The electric vibrators work in a cycle of production of the ring for 3-5 minutes, and the quality of compaction and the speed of compaction of concrete increase.

How are our competitors trying to save money?  Reducing the number of vibrators to one, while reducing the power (for example, the form of KS10.9 with a single vibrator) gives the form, the cycle of vibroconcrete of the concrete is increased, the quality of the compacting of concrete falls. Yes, the manufacture of forms of thin metal, reduced power of electric vibrators, reduction of the number of vibrators to one per vibroform - allows reducing the price of the vibroform, sometimes twice as much. But we must remember that such a light form is not designed for a sufficiently intensive and long operation. When making 3-5 items per shift, this form can last a long time. But when trying to use equipment more intensively, cases of detachment of vibrator areas are frequent, the form loses its geometry, etc.

Therefore, for the assembly of serious productions, we recommend products with years of proven design, reliable and durable.

Vibration Structure

The device of the vibroformit is not difficult: two metal cylinders, one of which is attached to a cone with a loop (the inner part is a core), and on the other - vibrators (the outer part). The mold is made of metal sheet and additionally reinforced with a profile - the core at the bottom, the outer part of the mold - at the top and bottom. The elements of the form reinforcement in the photographs: vertical metal strips (the first photo), the horizontal profile along the circumference of the outer part of the form (second photo). Installation of vibrators is carried out on specially made vibrator platforms. Assembly is carried out by placing the core in the center of the outer ring, fixing is done with metal fingers.

The standard vibroform of the ring is designed for the manufacture of concrete rings of wells with eyelets, this variant as the main one is described in GOST 8020. In the sidewall of the mold, at two diametrically opposite points, formers are installed. Purpose of the blower: create a hole (eyelet) in the side wall of the ring, which will be used to secure the lines and move the finished products. If necessary, the hole in the outer wall of the vibroform can be muffled. Appearance of the vibroform KS10.9 with the blowing agents is presented in the photo below.

Forms can also be manufactured without blowers, hoisting rings in this case will be carried out for metal loops, rigidly connected to the reinforcing carcass (for more details see the issue of reinforcement in the series 3.900.1-14). However, this option excludes the manufacture of concrete rings with a lock, which became the standard in many regions of Russia.

The price of the molds, regardless of the presence or absence of the transmitters, remains constant: it is important for the buyer to determine which products - with lugs, locks or metal hinges - will be more in demand in the region.

Forms for rings with a lock

For the manufacture of rings with a lock, the above-mentioned shapes with eyelets are used without any changes in the construction. Those. On this form, you can make simple rings with eyelets (with smooth ends of concrete products) and rings with a lock.

The lock is used to improve the sealing of the joint of individual rings. Molding of the groove and the crest of the lock is carried out using hollow-forming: upper and lower. Recently, the main option for the manufacture of cavities was metal (previously rubber could have been used). Advantage of a metal void former in front of rubber is increased stiffness. The standard hollow former for the ring KS10.9 is made of a metal sheet 16 mm thick in the form of 4 segments, which are fixed in a single ring by welding. If such a height of the lock is not enough, locks of 20 or 30 mm in height can be made of metal sheet.

In general, the lock is used for KS10.9 rings and, less often, for KS15.9 rings.

Hollowers can be made in the form of separate segments 25 mm high, joined in a ring before forming a concrete product. For the KS15.9 rings, the void-forming devices are made only in the modular version, 25 mm high.

In the construction of the wells with the lock, the movements of concrete (ferro-concrete) rings are practically eliminated relative to each other, which increases the strength of the entire reinforced concrete well construction and the degree of waterproofing achieved.

We offer molds for manufacturing concrete wall rings of the following basic sizes:

It is possible to manufacture vibroforms of concrete rings of any other dimensions. Prices for vibrating rings of other sizes can be found in price list.

Vibrateform is completed with common industrial vibrators IV-98 (KS 7.3, KS 10.9 and KS15.9 - 2 pcs, KS 20.9 - 3 pcs), rated at 380 V. In agreement with the customer, installation of vibrators designed for 220 or 42 V voltage is possible.

Together with the vibroforms of the well rings, they also buy:

Out-of-town facilities can not do without hydraulic structures: septic tanks, sewage collectors  and wells. The easiest way to build such objects with the help of rings of reinforced concrete. We will tell you how to make concrete rings yourself, how to make a mold for them and correctly mix concrete solution.

Decking

General information

Reinforced concrete rings are one of the best solutions  for construction. Specifications  concrete rings allow us not to worry about their integrity in the conditions of the freezing soil, which became the determining criterion in the selection of materials for our climatic conditions.

However, it is not always possible to purchase and deliver reinforced concrete products to the construction site, because the price of delivery often exceeds the cost of the product itself. Considering how much it costs to bury a concrete ring, the project can cost a round sum. In some regions there are no building warehouses or shops at all, so you have to do everything yourself.

For this, it is necessary to solve three tasks:

1. To make a mold  - formwork for the product;
2. Mix high-quality concrete mortar;
3. To lay the mixture in a mold, and upon completion of hardening, release the product from the formwork, without damaging the latter.

Important!
You can buy the completed formwork, but then all the sense of our invention is lost, because we are not going to open subsidiary production, and for one construction such an acquisition is unprofitable.

Mold Making

A ring of concrete is a section of a cylinder with a wall thickness of 80 to 160 mm. Thus, the product itself has an internal and external diameters, the outer diameter being greater than the internal diameter by 8 - 16 cm. Therefore, we need to pick up two steel cylinders with the indicated difference in size.

Advice!
  Concrete rings with a bottom can be made by filling the pre-slab at the bottom of the pit, into which the installation of the product will be made.

The standard ring has a height of 90 cm with an internal diameter of 1 m, with a wall thickness of 160 mm. However, we can depart from the accepted in GOST dimensions and proceed from the available tools available. The only thing to consider is the wall thickness of at least 10 cm and the height and weight of the product that are adequate for the subsequent installation.

Concrete rings with a lock are more difficult to make, so we will make products with an even edge.

Important!
  For our purposes, metal barrels, pieces of air ducts, pipes and other similar products will do.
  Also it can be small tanks or tanks, the main thing - a cylindrical shape, the difference in diameters within 10 - 15 cm and strong metal walls.

Now to the point.

To make the form yourself, step-by-step instructions will help you:

Important!
  The height of the inner cylinder should exceed the height of the outer cylinder by 10-15 cm for convenience in laying the concrete mix.

Making a Ring

How much it costs to dig a concrete ring - depends on the method of installation.

To make the ring, the formwork cylinders must be installed on a flat pallet. It can be a metal or wooden shield or a densely packed earth.

Then in the space between the cylinders it is necessary to install a reinforcing mesh, which can be purchased or manufactured from steel wire independently.

For the convenience of transportation and installation of the product in the grille should be inserted in the ears of thick wire or reinforcement diameter of 5 - 6 mm.

Between the cylinders, about half their height, we insert wooden spacers, the thickness of which is equal to the thickness of the walls of the future product. This is necessary so that when laying the formwork parts are not displaced relative to each other.

After that, mix the concrete mortar. To do this, take the cement grade M400 or higher and mix it with sifted and washed with clay sand in a ratio of 1: 2.5.

Then add water in the amount of 0.5 - 0.7 from the cement, so that the mixture was not too greasy, but not lean.

Add 5 pieces of rubble and carefully mix the mixture manually or with a concrete mixer. The finished solution is placed in a mold about 30 cm high, after which we carefully ram it with a piece of reinforcement or a holder from the shovel. You can lean against the formwork punch in the impact mode and gently produce a vibration of the concrete.

Then, similarly we lay the layer by layer, when we reach half, wooden wedges can be removed. Gradually fill the form and carefully level the upper edge of the ring, try to make it as smooth and smooth as possible.

Leave the product for three days in the shade under a canopy. After their expiration, take out the spindle of the internal formwork and open it inward. Then similarly remove the outer part of the form. The ring is left in place for 10 - 15 days, moisturize it and protect it from direct sunlight and wind.

Important!
  Plastic inserts in concrete rings allow you to get rid of the danger of leaks for 30 - 50 years.

Conclusion

If necessary, you can make a reinforced concrete ring yourself at home. The video in this article will help you better understand the technology of the product.