We have a concrete staircase that we recently cast, and on the sides, we initially thought of having classic balustrades with a cast "rail" on top. Now, I am desperately looking for a place where I can buy ready-made balusters at an affordable price. I have found one place, but they charge close to 3000 SEK each, and we need 8 of them... An alternative is to cast them myself, but then I need a mold, which also seems difficult to find. A company can import, and then we end up with almost 10000 SEK for a mold... It turns out to be quite a bit of money, so I would gratefully welcome tips on what else could be done!
Another thought is that instead of the classic round shape of the baluster, I could cast square ones in a mold that I could fairly easily make myself. The question then arises as to how thin I can make them. I'm thinking that 10x10 cm would look okay... Cast in fine concrete from Weber. What do you think, would this work if I reinforced with a rebar in the middle of the baluster?
Then comes the next detail, which is attaching the posts/balusters to the staircase. Should I let the rebar in the baluster stick out a bit at the bottom and then drill a hole in the staircase where I insert the rebar during installation? Or should I cast the baluster in place on the staircase?
More questions will probably pop up as I go along, but I hope I can get answers to some of the above!
I would have cast in place. The form for round columns is easily made in masonite. To achieve the rounded shape and hold-back, cut out the rounding from wide joists (220) and then nail the masonite to these joists. A column might consist of four similar forms. Assemble the forms on site where you will cast. Drill holes in the stairs and insert reinforcement bars. Similarly, the column should be cast with reinforcement bars both horizontally and vertically. The holes in the form where you pour the concrete are then filled with putty after you remove the form. For the best results, you should vibrate the concrete so it fills properly, but you can always use putty afterward as well. /CC
You have probably already found a solution to this, but I am in the process of casting a concrete fence********************. I am attaching a picture of how my fence looks. It will be painted once I have completed the whole thing. It will be grand.
Welcome to the forum! That looks really grand! I think many, including myself, would love to know more about how you did it and would appreciate some "construction pictures" if you have any.
Of course, I did. First, I cast a foundation for the entire fence. Glued the pillars together with stone glue and filled them with concrete. Then I bricked the supports that will hold the fence posts in place. In the groove, I filled fine concrete and placed the posts in it. I also laid rebar in the entire groove. Then welded rebar at the top of the posts so they stayed in place. The railings were then placed on the posts and also mortared in place. Then it remained to spackle and sand where needed. Painting remains, but I'll do that once the entire fence is complete.
Hi Michael, I still have quite a bit left to cast, so I need them at least until the summer of 2013. Maybe even the summer after that. But if you want to know where I bought them, send a private message instead, and I can give you the link. Alternatively, if you wait a couple of years!
Hi Christer. Just wanted to say that your fence is turning out absolutely wonderful. I have been searching for something similar as my husband and I are planning to create an Italian garden by the house. Would it be possible to get the link to where you bought the molds?
