From Paving Blocks to Kerbstones: Customizing Steel Moulds for Diverse Concrete Block Applications
Why Custom Moulds? Beyond Standardization
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While standard moulds can produce common blocks, customization is the only solution for:
Special sizes and shapes – such as curved kerbstones, interlocking pavers, or special blocks with drainage grooves.
Surface textures and patterns – imitating stone, wood, or anti-skid finishes.
High-performance requirements – high density, abrasion resistance, or complex draft angles.
Custom moulds allow manufacturers to:
Quickly respond to project-specific specifications.
Reduce material waste (by optimizing cavity design).
Increase the market value of finished products.
Key Technical Parameters for Steel Mould Customization
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At UNIK, we design moulds based on the following core parameters:
| Parameter Category | Key Considerations | Impact on Concrete Products |
|---|---|---|
| Material Selection | High-grade tool steel, alloy steel (e.g., Cr12MoV, 42CrMo) | Wear resistance, deformation resistance, service life (up to 1 million+ presses) |
| Machining Precision | CNC machining centers, wire EDM, EDM (Electrical Discharge Machining) | Dimensional tolerance of ±0.05mm, ensuring precise block interlocking |
| Surface Treatment | Chrome plating, nitriding, PVD coating | Smooth demoulding, corrosion resistance, surface finish |
| Cavity Layout | Single cavity, multi-cavity (e.g., 3, 6 cavities) | Production efficiency matched to press tonnage |
| Demoulding Design | Draft angle, position and number of ejector pins | Reduced chipping and cracking, higher yield |
Mould Design Strategies for Different Applications
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1. Paving Blocks
Requirements: High compressive strength, low water absorption, uniform color.
Mould Essentials:
Double-pressing design for consistent thickness.
Rounded edges to reduce transport damage.
Replaceable liners for different textures (e.g., I-shape, cloud pattern).
2. Hollow Blocks
Requirements: Light weight, thermal insulation, easy conduit installation.
Mould Essentials:
Precise core bar positioning system.
Large vent grooves to avoid delamination.
Hardened surface on core bars to prevent material sticking.
3. Kerbstones / Curb Stones
Requirements: Large size, high density, smooth chamfered edges.
Mould Essentials:
Reinforced frame to withstand expansion forces.
Split structure for easy replacement of worn parts.
Vibration isolation design to avoid resonance cracks.
4. Special Units (e.g., Grass Pavers, Tapered Blocks)
Requirements: Complex geometry, quick demoulding.
Mould Essentials:
Movable core or core-pulling mechanism.
Nitrided surfaces to reduce friction coefficient.
From Design to Delivery: The Custom Mould Standard Process
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Requirement Analysis: Customer provides final product drawings, target output, and press specifications (e.g., HESS, Columbia, or local machines).
3D Modeling & Flow Simulation: Analyzes concrete filling and vibration distribution.
Material & Heat Treatment Plan: Steel selection based on expected output (e.g., 45# steel for <500,000 cycles, alloy steel for >1 million cycles).
Precision Machining & Inspection: CMM (Coordinate Measuring Machine) verifies all critical dimensions.
Surface Treatment & Trial: Test pressing before delivery, either in-house or at a partner facility.
Delivery & Ongoing Support: Includes wear-part recommendations and maintenance guides.
Industry Trends: Smart Moulds & Modular Design
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As concrete products become more diverse (small batches, many varieties), two major changes are emerging:
Modular Mould Systems: Allow quick change of liners, logo plates, or core bars. One frame supports multiple product lines.
RFID Mould Management Chips: Track usage cycles and maintenance schedules, enabling predictive maintenance by connecting to MES.
UNIK is integrating these technologies into our mould solutions to help customers reduce inventory costs and increase production line flexibility.