Things To Consider When Making Concrete Fence Posts And Concrete Gravel Boards
Below are a list of things to stimulate your considerations and to help create a checklist for your business.
Please feel free to make notes and work through the questions to ensure that you have the very best chance of getting rid of those profit stealing gremlins and being successful quicker. Saving a few £ on buying cheaper may just be holding you back from levelling up and moving forward faster, see what you think, have you covered all these avenues in your business making slotted fence posts and gravel boards?
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- Materials - Sand Suppliers or Ballast Suppliers
This depends on your location but the following names are some starting points.
Breedon, Aggregate Industries, Tarmac
- Materials - Aggregate Stone Suppliers or Ballast Suppliers
This depends on your location but the following names are some starting points.
Breedon, Aggregate Industries, Tarmac
- Cement Suppliers, should it be in 25kg bags, 1 ton bags or a Cement Silo?
Tarmac, Dragon Alpha, Cemex, Remix
- If I buy 1 ton cement bags how do I unload them?
You can use a bulk bag unloader, which is as simple as lifting a bag with a forklift and placing it on an unloading device - See this link here for further info.
- Which Cement Silo is best for me?
This will depend on space availability, low level (Horizontal silos) need more room than Vertical Silos but the latter may require planning permission.
If you are considering a cement silo link here or aggregate storage bins or reach out to us here to discuss your requirements.
- Admixture - When do I need to add Concrete Admixtures?
If you want to achieve a stronger and smoother finish while speeding up the curing time admixtures are a good choice - Speak to us to discuss your application goals.
- Water - Can I use recycled water or do I need fresh water?
You can use a certain amount but it has to be within the EN/BS codes. Using the wash down water within the next mix can be very advantageous both in water saving but the good habit of washing down regularly will extend the lifetime of the mixer.
- Is Cold or Ambient water best for Precast Concrete Manufacturing?
Ambient and warm water will speed the reaction up allowing the concrete to cure quicker. Warm water is not recommended in summer time as this can cure too fast and create surface cracking.
- Concrete Mixers - Which one is best for me (There are 11 Types)?
This in depth article is coming soon, but in the meantime - contact us directly to discuss your budget, power supply and what your goals are.
- When it comes to the size of Concrete Mixer is "Bigger Better" for Concrete Fence Posts?
Bigger is not better, sizing the mixer is important and will help you both to save running cost and maintenance but also save on wasted time.
- How long do I need to Mix Concrete for?
This will depend on many variables. EN206 states 60 seconds for mixing, but oftentimes this is not enough because of the mixer not being powerful enough and the wrong type of mixer being operated.
- Can I mix concrete for too long?
Yes. Mixing concrete creates a chemical reaction and this can be sped up or slowed down with admixtures, but one this reaction has taken place there is no going back. Although you may be agitating the concrete the reaction has happened and you will then just be weakening the bonds. Many sites will not allow concrete if it is over 1 hour old.
- Is a Wet Mix (Concrete) better than a Dry Mix (Concrete)?
Wet mix has advantages of flowability and dry mix has advantages of strength. Both have their downsides but you can achieve the best of both by using an admixture.
- What is a W/C Ratio and why does it matter?
W/C is the Water / Cement ratio. The lower the water the stronger the concrete. This is a critical number to ensure you are maintaining throughout your production procedures.
- What strength Cement should I use - 52.5R or 42.5R or 32.5R?
This will depend on many aspects like cost, availability and required look of the concrete. There are many successful and varying mix designs but it is good to trial and prove a few so that when an ingredient is not readily available you can confidently adapt your mix design to another variant which you already know works and meets customer expectations.
- Which Type of Cement should I use, there are so many, how do I choose?
Same as above, but GGBS and PFA can change the colour and cost substantially.
- Who is the best Cement Supplier in the UK (ratings/Reviews)?
Sssshhh…We are in the process of writing a review and will be back soon on this with the pros and cons of each.
- What is Concrete slump and how much is too much?
Slump is the measure of how much a cone of concrete will slump down when stood up. If it stands up and does not slum down much it is generally considered a dry mix, slump down lots will be a wetter mix and easier to work with. Readymix drivers use slump as a commonly used measure when delivering concrete to site.
Slump is not as important to know as W/C but W/C is not easily measured without expensive equipment.
- Should I have use the same mix/slump for Concrete Fence posts as I use for Concrete Gravel boards?
Oftentime when we visit sites we will find a fencepost mix will be wetter than a gravel board mix, this is not always the best thing to do. We understand why it is done but there is a better way to get the same result.
Fence post mixes are often “runny” and actually scarily wet to try to help the concrete flow in and around the slotted section of the mould - we get that….the problem is that making it runny will weaken the post and your clients will suffer and there will be a longer curing time. If you invest in a Vibration Table that has adequate force (not too much - not too little) then you can work with a stronger mix and overcome the flowability challenge also. - See our Vibration Tables Solutions and then give us a call to discuss the best one for you.
- What is the best way to get the Concrete from the mixer to the Concrete moulds?
We have used and applied successfully for many years our integrated Rake-Off Table - See Images Here, this integrates with our Vibration Tables. This allows you to use the benefit of gravity to fill your moulds and will also reduce your manual handling efforts.
- Should I use a Conveyor, Concrete Chute, Concrete Skip or Wheel Barrow to get the Concrete from the Mixer to the Fence Post Moulds?
This will depend on your current factory configuration. As above mentioned the best way to successfully produce is to work in one direction and utilise gravity, it will also depend on current factory layouts. If you are considering investment and looking to get improvements and more output - reach out to us and we can help you to get the best out of your resources - Reach us here.
- What type of Concrete Fence Post Moulds should I use?
Urethane is the best but has the biggest initial outlay.
Polypropylene is a great alternative and lighter to work with, these won’t last as long but allows you to work with a lower initial investment.
If you require any moulds we can help you with these.
- What type of Concrete Gravel Board Moulds should I use?
Urethane is available for gravel boards but is not very common.
ABS is the most often used mould for Gravel Boards. Make sure to include a Mould Holder when ordering to ensure you have a long life for the mould, you can also use the holder time and again when you replace the ABS mould. We use a special construction and joinery process to ensure the best possible result for your Mould Holders.
- Should I use Urethane, Cast Urethane, Thermoformed Plastic or Steel Concrete Fence Post Moulds?
This will depend on many factors, we can help you work through this decision to achieve the best for your specific situation and how many you require. Reach out to us here or view images on this link here.
- Should I use Cast Urethane or ABS Plastic Gravel Board Moulds?
ABS plastic is know to have very good durability and resistance properties, we always recommend ABS Gravel Board Moulds along with Custom Mould Holders - See Images Here.
- Can I make the Gravel Board Mould Holders/Carriers myself - Is it worth it?
Many start up companies will attempt to solve this problem by building some themselves. We have proven that there is a very specific design that works best along with specially machined timbers. If you are interested, ours will probably be the most expensive, and we are proud of that because our holders are made to last and are superior - you win!
- Should I use a One Stop Shop or source from Multiple Suppliers for my Precast Concrete Supplies?
Many customers who rely on us for their entire production range, this has allowed them to focus on doing the work and allows us to help them grow faster and more easily instead of try to save a few pounds here and there we can help you make concrete better and faster which will be more profit each and every time you cast where as saving a few pounds when buying equipment is only a once off saving.
- What Release Agent should I use for my Concrete Moulds?
Release agent’s are a hidden warrior, get the right one and you will be winning wars. Some release agents will have a strong pungent smell and others will not. We always recommend using a Low Odor Release Agent for the sake of your operatives. Always make sure to wear a suitable mask and face covering when applying it because airbourne vapours are detrimental to you and your staff’s health. We stock 20, 205 and 1000L release agent ready for you.
- Are all Release Agents the same?
No - As above.
Some release agents are water based and some are mineral oil based. Water based release agent require you to wait until the water (which is the carrier) to evaporate, so it depends on your factory procedure if this will work for you.
- What thickness steel rebar do I need for my Concrete Fencing?
5.5mm Steel
- Best 5.5mm Rebar Supplier for Fence Post and Gravel Boards (Ratings/Reviews)?
Sssshhh - We are working on a UK wide supply list. This will help you to get the pros and cons of each supplier.
- How many rebar spacer clips do I need per Concrete Fence Post?
Use a minimum of 3, 4 is better as this will ensure that the steel is kept consistently in position.
- How many rebar spacer clips do I need per Concrete Gravel Board?
Use a minimum of 3, 4 is better as this will ensure that the steel is kept consistently in position.
- Do I need a rake-off table between my Concrete Mixer and my Vibration Table?
If you can position your mixer higher up you will get greater production benefits, this may require you to elevate the ground around the mixer, but you will continue to get the benefits of it.
- What type of Vibration Table do I need?
Let chat about this one as there are many ways to achieve your desired result, some work better.
We have multiple types in stock and ready for immediate dispatch, both 3phase and 1 phase power supply inputs, we can customise to your requirements….if you feel like it.
- How long do I need to vibrate my Fence Posts for?
This is not straightforward to answer - The more powerful the table the less time it needs to vibrate, if there are twin motors then this will also speed the process up. Vibration is a noisy process so the less time spent doing it the better for everyone.
- What should my Concrete Fence Post look like once Vibrated?
Creamy finish on top…but be careful, too much vibration will separate the mix.
- Do Concrete Gravel Boards Need as much vibration as Concrete Fence Posts?
No, these are easier to vibrate as they have a simple and low profile.
- How long will it take for the Concrete to cure?
Concrete carries on curing almost forever. That said you will achieve majority of “strength” within 24 hours and then 28 days.
- Can I remove my Concrete Fence Posts form the Concrete Mould within 8 hours?
If done right yes you can but you may require some admixtures to enable you to do this. Most companies only run one shift so they recast between 18-24 hours which is a better time frame to work to.
- Do I need to cover my Concrete Products while they cure?
Covering your concrete will help to keep the surface from drying too fast (creating plastic shrinkage), it is also a good way to get some heat into the product during winter.
- Is it true that Concrete creates heat while curing?
Yes - The concrete reaction “curing” will elevate temperatures of the product.
- How do I take the Concrete Fencing Products out of their Concrete Moulds?
Ensure you have a soft timber or rubber faced bench. Turn the post over using two people to lift and bump the mould downwards. A good mould will not allow it to “fall out” or neither will it need to be “banged out”
- Best way to stack Concrete Fencing Products?
Stacking demoulded concrete products is an important step which should only be done once to minimise wasted time and damaging products. A thin packer strip 5-10mm is used to separate each layer, depending on how you are selling and distributing the product will depend on how high or wide you stack….always keep in mind the onward journey…..most pickups or flatbed transits are 1000kg payload max.
- Best way to stack Concrete Gravel Boards?
Vertical stacking (12” high) is the best way.
- How long do I need to keep my Concrete Products before using or selling them?
This depends on the season and your availability to store product. Most of our clients would work to keep a rotation of stock between 2 - 4 weeks.
- How much should I sell my Concrete fence Post for?
Price vary largely up and down the country but if you set yourself to provide a product you are proud of you can sell for a higher price, this will allow you to serve your clients better and reinvest in building your business, sell lower than your competitor and you will starve yourself of cash to build your business.
- Can I make more money selling Concrete Gravel Boards than Concrete Fence Posts?
There is excellent money to be made by selling a high quality product. Too many manufacturers don’t care and lose business without even knowing why.
- How to do a Concrete Crush test to check the strength of my Concrete Products?
Speak to your cement supplier, they will often have equipment to test with. If you are building your business and want to make it robust you should have multiple mix designs which you can switch to if your standard supplier can supply, getting a strength test “crush test” will help you to tweak your mix designs to increase profit and provide a backup supply line plan.
- How to calculate how much power my Concrete Mixer uses while making my Concrete Products?
Use the kW of the motor x time to mix = Power consumed. You can even x this by the cost of electricity and work out the cost per mix and cost per post. You will soon decide whether to leave that mixer running or not.
- What machinery do I need to make Concrete Fence Posts?
This depends on if you are starting up or adding to an existing concrete business.
Things you need are -
Concrete Mixer
Rake off table
Vibration table
- How much do I need to invest to get started making Concrete Fence Posts and Gravel Boards?
Depending on how fast you want to build your business and what mindset you have.
We will often help a client get started for less than £30,000 with a complete set up. We have also set up clients for £250,000 with semi automated equipment, but that was an ambitious client who is now market leader in their region of the UK. We have a solution for everyone, but we don’t sell cheap products, we sell true solutions.
- How quickly should I expect a Return On Investment (ROI)
Automation and optimisation will always speed up the ROI.
You should try to achieve a 0.5 -1 year ROI on consumable type items, capital machinery can be up to 3-5 year.
ROI should be calculated by time saving, cost saving, product cost reduction and increased output and maintenance reduction.
- Do I need skilled labour for my team?
Depends on your mindset!
You can invest in machinery and use less people or you can have a production optimiser who can streamline things, but this will still be dependent on the people doing the right thing.
Machinery will always win.
- How many people do I need to be an efficient concrete manufacturer?
This once again depends on the investment budget.
One of our clients can operate on his own (YES ONE PERSON) and produce 140 items a day (plus other precast mouldings), he chose to do this because he does not want to be worried with staff so he invested in the very best optimisation methods that we have.
- Should I buy Ready Mixed Concrete or make my own Concrete, how do I calculate this properly?
Unless you have a readymix company beside you then making concrete yourself will always pay off.
- What sort of profits should I expect to make with Concrete Fencing Products?
Depending on where you are in the country……but we know of clients who struggle to make £30,000 profit a year from their small business to others who are making £60,000 per operative - please note we do not claim you will make any money and these figures are not typical.
- What other Concrete items should I make along with Concrete Fence Post and Concrete Gravel Boards?
You need to ask your customers, there is nothing better than asking them!
Coping stones and Pier Caps are a natural add-on to fence posts and gravel boards so that could be a next step…
- What is the minimum space needed to make Concrete Fencing Products efficiently?
Space is often the hardest thing to change. We work with you to optimise your existing workspace and build a plan with you to take you to the next level.
- Is there such a thing as a Concrete Fencing Starter Kit?
Yes we can supply from stock (often from stock, but upto 6 weeks if busy)
- How long does it take to learn all the Tips & Tricks and who could help me to sort all of these questions out quickly?
We are always available to discuss challenges and next steps with our progressive clients, that said, we can soon spot a waster!
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