Okay, I've chipped away a substantial section with a Hilti 7 KG, and to get straight edges, I used the larger angle grinder, both on asphalt and garage floor. Houses aren't straight, so unfortunately, there's a 2 cm difference between the left and right side, but no one is likely to notice. I have also drilled and inserted rebar, with a total of 3 long longitudinal rebars that will be tied together with steel wire at various heights.
Nearly 20 25-liter bags of Finja Coarse Concrete have been purchased, and the plan is to mix it a bit thicker on the top layer so that we can shape a straight upward slope to a small rounded plateau where the door can rest.
The question is, however, how durable this will really be, as one has seen quite a few castings that have cracked over the years. In this case, we receive constant deliveries of pellets that are brought directly into the garage with a hand truck. Most often, the delivery person drives against the edge at the entrance/exit, failing to sufficiently raise the hand truck, resulting in the rusted edge being worn down.
Do you think this casting will hold up even with pellet deliveries? If one were to get a ledge iron, how would it fit into my design?
If you are afraid that it will crack, you need more reinforcement bars. The more iron, the fewer cracks, as long as it is possible to achieve a good covering casting. That is, there must be room for the stones in the concrete and the vibrator that needs to go down between the bars. In your case, there is direct space for 4-5 longitudinal bars divided into an upper and a lower layer. Then you should also have stirrups that bind the upper and lower layers together to achieve cooperation. All this might seem like overkill, but if you want something without major cracks, reinforcement is the key. Completely crack-free concrete is not possible, but the more reinforcement used, the smaller the cracks become, though they become more numerous. Because that's what reinforcement does, reduces the few large cracks to become more numerous but smaller. Where the smaller ones are not visible to the naked eye and then the concrete is perceived as crack-free.
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