Fence casting guide

REQUIRED MATERIALS

1. FENCE MOLD SUPPORT FRAME

- 1 rectangular steel tube, 6 m long, 50×30×2 mm;
- 1 rectangular steel tube, 6 m long, 15×15×1.5 mm;
- 1 OSB board, 8 mm thick, 2500×1250 mm;

2. POST MOLD SUPPORT

- 1 wooden plank, length of the post mold, 13×2 cm;
- 2 wooden planks, length of the post mold, 15×2 cm;
- 2 wooden pieces, 17×15 cm, for the support end caps;
- 2 wooden pieces for the support handles (approx. 19 cm long);

3. CONCRETE (quantity for one mold)

- Sodium silicate (water glass);
- 8 liters of water;
- 2 buckets (10-liter capacity) of gravel aggregate, 4–8 mm grain size;
- 1 bucket (10-liter capacity) of cement (52.5 – standard compressive strength [MPa]);
- 1 bucket (10-liter capacity) of sand;

4. REINFORCEMENT

- 3 ribbed steel bars, Ø8 mm, length of the fence mold;
- 4 ribbed steel bars, Ø8 mm, length of the post mold

5. CLEANING

- Water;
- Food-grade vinegar;

SUPPORT ASSEMBLY

1. FENCE MOLD SUPPORT FRAME

- Cut the 50×30 mm rectangular tube in half (3 m each), then cut 50 cm from each 3 m section. You must obtain 2 pieces of 2.5 m and 2 pieces of 50 cm.
- Cut the 15×15 mm rectangular tube into pieces of approx. 60 cm.
- Weld the tubes together as shown in the images (the interior dimensions of the support must match the fence panel size, e.g. 200×50 cm):



- Cut the OSB board and place it inside the support frame:



- Trim the mold edges with an angle grinder and place the mold into the support:



2. POST MOLD SUPPORT

- Fasten the wooden boards together with self-drilling screws:

(the 13 cm wide board at the bottom, the two 15 cm wide boards on the sides, then the two end caps and the two handle boards, as shown in the images).



WORKING METHOD

- Rinse the mold with clean water.
- Mix 80 liters of water with 1 liter of sodium silicate in a plastic barrel. Warning! Do NOT wash yourself with this water!
- Add to the concrete mixer: 8 liters of the prepared water, 2 buckets of gravel aggregate, 1 bucket of cement, and 1 bucket of sand, then mix thoroughly.
- With the mold placed in the support, pour the concrete using a 5-liter bucket, gradually, until the mold is half full.
- Shake the mold slightly so the material spreads evenly, then add the 3 steel bars, evenly spaced along the length.
- Fill the mold completely with the remaining material and shake again until fully leveled.



- For the post mold, proceed similarly (fill halfway, place 2 steel bars on the sides, fill completely, then add the remaining 2 steel bars, shake the support well to level the material and remove air bubbles.).
- Cover the molds with plastic foil to retain moisture and prevent cracking
- Leave to dry 24 / 48 / 72 hours, depending on outdoor temperature: 24 h in summer, 48 h in spring/autumn, 72 h in winter (indoors, if the room is unheated).

DEMOLDING

- After complete drying, place 3–4 wooden boards on the ground. Bring the support next to them and gently tip the panel onto the boards. Then carefully lift the support and the mold.



- To demold the post place boards underneath, remove the end caps and handles, turn the support upside down, and remove it.
- To remove the mold, gently loosen the first edge along the entire length of the post, then pull the mold toward you and lift it sideways.



STORAGE

- Store the panels stacked, one on top of another.



CLEANING

Pour water and food-grade vinegar into the molds and remove all residues using a soft sponge.

INSTALLATION

Step 1 – Take measurements

Mark the fence line using string and stakes.
With marking spray or chalk powder, mark the ground areas to be excavated for the posts.

Step 2 – Level the ground

Level the soil to avoid gaps at the base of the fence.
This is done by smoothing the terrain or adding soil where holes or depressions exist.

Step 3 – Install the posts

After marking and digging the holes, install the support posts at equal distances and at the correct height.

Pour concrete (manually or with a mixer truck) and level it with a straightedge or trowel.

Install wooden formwork for the foundation, ensuring consistent dimensions along the entire fence. 

Drying time varies depending on cement type.

Follow recommendations for watering the foundation after pouring to prevent cracks and loss of durability.

Once fully dry, remove the formwork and continue building the fence.



Step 4 – Install the fence panels

Insert the fence panels from top to bottom, one by one, until the panel is complete. One fence section can consist of 3 or 4 panels, depending on the desired fence height.