How to make your own deep concrete vibrator


Home |Technique and materials |Do-it-yourself deep vibrator for concrete

Date: May 23, 2017

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Concrete is widely used in construction and repair work. The material is indispensable due to its increased strength and reliability, which allows concrete structures to be used for a long time. An internal vibrator for concrete helps to ensure a homogeneous structure of the monolith, compacting the solution and removing air inclusions from the mass.

Today there are many types of vibration compactors available. Their purchase is advisable if concrete is poured in significant volumes. With small foundation dimensions, using available power tools and available materials, you can save financial resources and make a concrete vibrator with your own hands. Such a device will practically not differ in operating efficiency from its factory counterpart.

Let us dwell on the principle of operation, purpose, types and technical characteristics of the device. Let's consider recommendations for self-production.

Since air still gets in when mixing and laying the solution, you have to remove it with something

Why do you need a deep concrete vibrator?

During the mixing process, the concrete solution is actively saturated with air. This reduces the strength characteristics of concrete structures and negatively affects the reliability and service life. You can avoid negative factors if you use a submersible vibrator, the main functions of which are:

  • ensuring a uniform consistency of the concrete solution;
  • elimination of air cavities in the thickness of the massif;
  • removing excess moisture from the concrete composition;
  • increasing the strength characteristics of the material.

After vibration compaction, the plasticity and compliance of the concrete composition increases. The intensity of concrete shrinkage also increases and the curing time is reduced.

Site

Centrifugal type devices. There are directional and circular area vibrators. The equipment compacts the concrete solution as much as possible in the production of floor slabs and other concrete horizontal surfaces of small thickness. The operating principle of the devices is based on the action of a plate on the top layer of the solution, generating mechanical vibrations.

Advantages:

  • increasing the strength of concrete up to 20% while saving cement up to 15%;
  • reduction of concrete hardening time.

Flaws:

  • high energy consumption;
  • high price.

Operating principle

In formwork with reinforcement filled with concrete, it is problematic to mix the solution manually. Using a steel rod to “bayonet” a concrete mass does not bring the desired effect. There is a need to use a device that transmits high-frequency vibrations to the solution.

To remove air and improve the connection between concrete particles - these are the tasks that a construction vibrator performs

Based on the principle of impact on concrete mortar, devices are divided into types:

  1. Submersible-type vibration compactors (deep), which transmit high-frequency vibrations to the concrete mass through the body of the submersible nozzle.
  2. External platform-type devices placed on the formwork that transmit vibration to the concrete mass.
  3. Surface devices, the vibration from which is transmitted to a specific work area where the concrete solution is laid.

A submersible device that creates high-frequency oscillations in the thickness of the massif is widely used.

The operating feature of the vibrating compactor, which implements this principle, is based on the removal of air bubbles from the concrete solution. A high-frequency vibrator transmits vibration energy to the concrete through the working element, mixing it. Lighter air bubbles tend to rise outward. This increases the moisture resistance of the monolith, relieves internal stress, and reduces the likelihood of shell formation.

Purpose

The prepared concrete solution, despite thorough mixing, remains heterogeneous, which reduces the characteristics of the monolith. In addition to cement laitance, crushed stone and sand, it contains water and air bubbles.

If concrete is simply poured into the formwork, the result will be a structure that is heterogeneous in structure. The use of a vibration compactor for concrete increases the fluidity of the mixture without additional additives, due to the movement of its components. Air inclusions are pushed onto the surface of the monolith, and the fillers are evenly distributed throughout the volume.

After vibration compaction, the volume of concrete poured into the formwork is reduced by 30%. This effect occurs due to getting rid of air-filled voids and more dense packing of sand and crushed stone. As a result, the strength of the massive structure reaches its maximum value and high density for a given grade of concrete.

Deep vibrator device

The submersible vibration compactor of the electromechanical type is designed quite simply. It consists of the following parts:

  • an electric motor, which is a source of energy;

Submersible Portable Concrete Vibrator

  • a flexible shaft that acts as a transmission mechanism;
  • a generator attachment that creates high-frequency vibrations.

The vibrating tip can have the following shape:

  1. Cylindrical. This attachment is called a vibrating mace and is used when the solution is of normal thickness.
  2. Conical. The tip is a vibrating bayonet used to compact thick mixtures.

The working part may include:

  • group of vibration attachments;
  • vibration tips of various diameters;
  • one or more vibrating bayonets.

The main elements of the vibrating attachment:

  1. Cylindrical body made of stainless steel pipe.
  2. Roller bearings centering the flexible shaft.
  3. A bushing that converts rotation into vibrations.

Incorrect use of vibration will not only bring no benefit, but can also cause harm: excessive duration of exposure will cause stratification of the solution, which will negatively affect its strength

Principle of operation

The basis of the design of various types of devices is a vibration unit that generates frequency vibrations sufficient to squeeze out air bubbles from the structure of unhardened concrete. A shaft with an eccentric immersed in the solution can be connected to a pneumatic, diesel or electric motor.

They impart rotational movements to the shaft through a steel cable, which is covered with a special casing. The most productive are vibrators equipped with diesel engines. They are used for large-scale concrete work. Vibrators with single- or three-phase electric motors 220 V or 42 V can handle small volumes of concreting.

Submersible vibrator - varieties

Submersible type vibration compactors differ in their design features. Applicable:

  • electromechanical devices operating from a motor with a supply voltage of 220 or 380 V and a frequency of 50 Hz. Torque through a flexible shaft 1.5–6 m long is converted into vibration of the working body;
  • high frequency vibration compactors driven by a motor with a frequency of up to 200 Hz. The voltage converter reduces the motor power to 42 V and ensures the safety of concrete work;
  • vibrating compactors with hydraulic drive. A design nuance is the adjustment of the oscillation frequency of the hydraulic motor, which develops pressure up to 120 bar;
  • pneumatic devices controlled by a pneumatic motor using a release valve. The devices are easy to maintain and are used in the production of reinforced concrete products;
  • electromagnetic type vibrators. A constant frequency of oscillation is created by a spring-loaded armature using an electric magnet. The amplitude of oscillations is affected by the weight of the armature and the elasticity of the springs.

Based on size and performance, devices are divided into the following types:

  1. Small-sized vibration compactors with low productivity. They are used in the construction of private facilities.
  2. Standard vibration compactors with vibration frequencies up to 20 thousand per minute. Used in industrial construction.

A high-frequency vibrator is widely used, providing effective compaction of the concrete mass due to its increased efficiency.

High frequency deep vibrator

Warranty service

The factories provide a warranty for portable construction equipment and its components for 1 (one) year, provided that the technical requirements for its care are met.

In the event that equipment malfunction occurs as a result of incorrect actions by the consumer, the plant is not responsible for it. For example: the rupture of a sleeve due to the hardening of “concrete milk” in its cavity indicates that the client did not clean the flexible shaft after completing the concrete compaction work. For this reason, the manufacturer is not responsible for this type of breakdown.

For industrial multi-station devices (gasoline, diesel, high-frequency and electric vibrators) and spare parts for them, the plant issues a warranty for a period of 1000 hours of operation over 1 calendar year.

But in cases where:

  • the storage conditions of the device were not met (damp room, moving parts of mechanisms not cleaned and lubricated, bending of the flexible shaft not permitted...);
  • the mace overheated due to working in a waterless environment;
  • the motor failed due to low voltage in the supply network;
  • the mace was operated in a state clamped between reinforcing bars;
  • there was no lubrication of the flexible shaft cable and the drive and mace bearings,

and the device fails, the manufacturer does not provide free restoration of construction equipment to the consumer.

High-frequency vibrator – features of choice and characteristics

When choosing a vibrator for concrete compaction, you should consider several factors:

  • nature of construction work;
  • features of reinforced concrete structures;
  • depth of the concrete mass;
  • mesh size of the reinforcement mesh.

For example, to compact a slab-type base with a small thickness, it is enough to use a device with an intermediate shaft of up to 3 m. If the depth of the formwork filled with concrete exceeds 2 m, you will need a vibration compactor with a shaft up to 5 meters long. The diameter of the vibrating tip should be 50% smaller than the mesh size of the reinforcement mesh. This will ensure the necessary penetration of the nozzle and reduce the likelihood of contact with the reinforcement.

The characteristics of deep-hole devices powered by an alternating voltage network differ in the following parameters:

  1. Supply voltage (220 or 380 V).
  2. Availability of a residual current device.
  3. Electric motor power (from 1 to 1.5 kW).
  4. The frequency of vibrations created by the working body (12–20 thousand rpm).
  5. Performance depending on motor power and oscillation frequency.
  6. The length of the intermediate shaft, if necessary, is up to 10 m.

The most effective are high frequency

Note to craftsmen

When compacting concrete with an internal vibrator, you must adhere to the appropriate recommendations.

  1. The freshly poured solution may contain about 50% air. The percentage depends on the brand of cement and the degree of its mobility. These voids must be eliminated using a deep vibrator.
  2. The battery-powered vibrator must reach all places in the poured foundation, otherwise the remaining voids will cause trouble in the future.
  3. Remember that under no circumstances should you stop pouring the foundation, so you must constantly monitor the operation of the vibrator so that it does not break at an unforeseen moment.
  4. To avoid the formation of air voids in the solution, the foundation must be poured from a low height.
  5. It is recommended to immerse the tip of the device into the solution only vertically and not make horizontal movements.
  6. You must always monitor the distance between dive points. It should not exceed 10 sizes of the diameter of the tip itself.
  7. When pouring a layer-by-layer foundation, the tip must be immersed in each previous layer by at least ten centimeters to ensure the strongest possible adhesion of all layers.
  8. If you hold the vibrator at one point for too long, the concrete may delaminate. The operating time of the device is from 5 to 15 seconds. The frequency depends on the brand of cement and the power of the vibrating device.
  9. The working tip should not touch the walls of the formwork or reinforcement structure.
  10. The tip must be removed carefully, making slow “up and down” movements so that street air does not enter the place where it was located.
  11. If there are no bubbles on the entire surface of the concrete, then the work was done correctly.
  12. A factory vibrator cannot be turned on “idle”, as this will damage the device and shorten its service life.

Other options for making your own vibrator at home

Although making it from a drill or hammer drill is the most common, there are other options for assembling an internal vibrator at home. It is enough to select the appropriate vibration source and adapt a suitable vibrating tip to it.

Video: deep vibrator from a water pump motor

The main advantage of concrete vibrators made from improvised tools is that you do not have to spend money on the device, and after finishing the work it is dismantled, and the components can be used for their intended purpose.

Video: deep vibrator from a trimmer

In order to pour a monolithic foundation yourself, a vibrator made from a drill or hammer drill, assembled at home from improvised materials, is perfect. Such a tool is not suitable for large-scale construction, but will be simply irreplaceable in the construction of structures for a summer house or country house. It should be noted that if the length of the device exceeds one meter, you will need an assistant to work. When assembling a vibrator at home, you need to make all joints as reliable as possible, since the concrete solution creates strong pressure on the device and is able to actively counteract vibration vibrations.

How to make a vibrator for concrete with your own hands

For self-production, you can use one of the following devices:

  • electric drill;
  • small hammer drill with power up to 1.5 kW.

Make a submersible vibrator according to the first option by preparing the following equipment and components:

  • Electric drill with a power of 0.65–1.0 kW.
  • Welding machine with electrodes.
  • A hacksaw for metal.
  • Stainless steel pipe with a diameter of 40–45 mm.
  • Steel rod with a diameter of 12–15 mm.
  • Flexible cable in a waterproofed casing of the required length.
  • Bearings in the amount of 2 pieces, corresponding to the internal diameter of the pipe and the dimensions of the steel rod.

A construction vibrator can be made on the basis of any power tool with an adjustable speed

Carry out manufacturing following the sequence of operations:

  • Cut a piece of pipe 450–550 mm long.
  • Weld an eccentric at the end of the steel rod.
  • Install bearings onto the rod with weighting material.
  • Insert the assembled assembly into the pipe.
  • Weld the end of the pipe.
  • Seal the tip exit.
  • Connect the cable to the attachment and drill.

The principle of operation of the device is to convert the rotational movement of the flexible shaft into vibrations of the nozzle thanks to the installed eccentric. By adjusting the speed of the electric drill, you can change the amplitude of the oscillations.

For manufacturing, you can use a hammer drill. Required:

  • steel pike;
  • support washer.

The length of the peak is selected depending on the depth of the formwork. A washer is welded at the end of the rod.

The device is operated in rebound mode. A rod with a washer installed in the hammer drill cartridge rests on the bottom of the formwork and transmits vibrations to the concrete mass. Using a hammer drill with an attachment, it is easy to process significant volumes of solution in a limited time.

TOP 10 factory products

Our review examines the most popular equipment models, which receive the most adequate positive reviews. We have tried to include products from a wide price range and with different technical characteristics. Prices are for comparison purposes only.

RED MAYAK EPK-1300 – from 13,200 rub.

One of the most popular models of high-frequency submersible vibrator is produced at Yaroslavsky OJSC.
This company has a long history and therefore its products are trusted by professionals. It features convenient transportation due to the presence of a handle, good stability due to its wide base, and does not require special maintenance. With a relatively low power consumption, it provides high efficiency in compacting concrete mixtures and is used for work with reinforced structures, including eliminating voids in corners. Main technical characteristics of Krasny Mayak EPK-1300

ParameterMeaning
Typedeep
Power1300 W
Nutrition220 V
Vibration frequency17100 vibrations/min
Flexible shaft length3 m (4.5/6/9 m)*
Vibrating tip diameter51 mm
Dimensions350x180x270 mm
Weight26.9 kg

*optional.

Below is a short video from which you can learn about the design of the EPK-1300 vibrator, as well as the features of its operation.

Caliber VER-1500 – from 4100 rubles.

The Caliber VER-1500 model is supplied without a flexible shaft and a mace - the manufacturer provides the buyer with the opportunity to select them optionally.
This will add another 3-4 kg to the mass of the vibrator, and will also increase its cost by about 1000-1800 rubles. The main advantage is portability and ease of use. The entire set of equipment can be moved within the length of the power extension cord. As for the brand, this is good China, originally from the Russian Federation. Positioned as an affordable and high-quality tool for household use. Important technical characteristics of Caliber VER-1500

ParameterMeaning
Typedeep
Power1500 W
Nutrition220 V
Flexible shaft length(1/1.5/2 m)*
Vibrating tip diameter35 mm
Dimensions400x140x300 mm
Weight3.2 kg (+3.4 kg other components that are not included in the kit)

*optional.

We were unable to find a suitable video, but most similar models work in the same way, for example, Sturm CV71101, Grost VGP 800, etc.

Sturm CV7120 – from 14,000 rub.

Do you need something reliable and durable, but don’t plan to buy expensive equipment?
Then you should pay attention to the portable unit Sturm CV7120. An option for those who have no prejudices about products from China. The brand itself is German and has been familiar to Russian consumers for more than ten years. The product is equipped with a four-meter flexible shaft and is suitable, for example, for pouring columns or reinforced concrete walls of basements. Let’s immediately make a reservation that when purchasing this product, it is advisable to immediately take care of purchasing a spare shaft with a mace. There are frequent complaints about their lack of availability from large suppliers. Important information about Sturm CV7120

ParameterMeaning
Typedeep
Power2000 W
Nutrition220 V
Vibration frequency18000 vibrations/min
Flexible shaft length4
Vibrating tip diameter38 mm
Dimensions660x750x300 mm
Weight5.15 kg

What result is achieved with this thing? We haven’t found a high-quality video review of this model, but everything looks something like the one in the video below.

Among the equipment of a similar design is Energomash BV-71200.

Hervisa Runner Plus 52 – from 78,000 rub.

Another representative of compact vibrators for concrete is the professional model Hervisa Runner Plus 52 from a well-known Spanish manufacturer.
The company has over 30 years of experience in the development and manufacture of vibration equipment for construction. It is not surprising that this specimen made it into our TOP, because it has its own voltage converter, durable drive and flexible shaft. In addition, the device is equipped with protection against overheating, current leakage, and stop protection for the safest and most comfortable operation. With its help you can process up to 40 cubic meters of mixture per hour! Characteristics of the Hervisa Runner Plus 52 vibrator

ParameterMeaning
Typedeep
Power1500 W
Nutrition220 V
Vibration frequency12000 vibrations/min
Flexible shaft length(5/7 m)*
Vibrating tip diameter52 mm
Dimensionsnot specified
Weight(15/17 kg)*

* depends on the configuration.

Red Mayak IV-98E – from 10,000 rubles.

In our review we have already encountered products from this plant, but we cannot ignore the platform-type model Krasny Mayak IV-98E.
Such equipment is attached to the formwork or intermediate structure, the main thing is that the vibrator axis is located horizontally. Despite its purpose, it is a fairly compact design in a durable steel case that provides protection for the engine, shaft, unbalances and other components. In addition to being used for compacting concrete mixtures with high-density reinforcement, IV-98E can be used in the manufacture of vibrating tables, vibrating plates and other equipment. Important characteristics of the product Red Mayak IV-98E

ParameterMeaning
Typesite
Power900 W
Nutrition220 V
Vibration frequency3000 vibrations/min
Dimensions365x235x250 mm
Weight22.5 kg

This equipment is designed similarly to the IV-99B, presented in the video below.

Wacker Neuson AR 36/3/230 – from 18,000 rub.

The Wacker Neuson AR 36/3/230 model is a kind of alternative to the above product from a domestic manufacturer.
This is a German brand with production in Germany. It costs more, but it is the one that is trusted by the largest construction companies that build projects around the world. It is economical and durable, can operate in two axes without the risk of damage to the drive. Mounting to the formwork is not included in the kit - this must be taken into account before purchasing the vibrator. The cost of a proprietary mount can reach half or more of the cost of the vibration equipment itself. Basic data on Wacker Neuson AR 36/3/230

ParameterMeaning
Typesite
Power400 W
Nutrition220 V
Vibration frequency3000 vibrations/min
Dimensions289x227x103 mm
Weight7.2 kg

The operation of such vibrators is clearly demonstrated in the following video.

Wacker Neuson AR 64/3/400 – from 70 thousand rubles.

If the equipment must work under wear and tear for the longest possible time, then you need to focus on a professional model of a vibrator such as Wacker Neuson AR 64/3/400.
This equipment is equipped with an electric motor powered by a three-phase network; the design of the unit provides for convenient installation and maintenance. Works on the basis of the same equipment as the previous product. Summarizing the above, AR 64/3/400 in a number of several pieces is suitable for construction companies for the construction of reinforced concrete walls or reinforced concrete plants. Basic data on Wacker Neuson AR 64/3/400

ParameterMeaning
Typesite
Power800 W
Nutrition380 V
Vibration frequency3000 vibrations/min
Dimensions289x227x103 mm
Weight18.7 kg

Makita BVR450Z – from 13,000 rub.

The name of this brand is familiar to many who have at least once held a quality power tool in their hands - Japanese Makita is valued for its excellent quality and reasonable price.
The Makita BVR450Z deep vibrator model is notable for the fact that this portable device is powered by a battery. Sometimes it is very convenient not to be tied to an extension cord. The length of the flexible shaft is short, which hints at a rather limited use of the tool, for example, when pouring floors, screeds, shallow strip or slab foundations. However, we immediately warn you that by default the product is not equipped with a battery - it will have to be purchased separately, and this is another plus of 5-6 thousand rubles. Main characteristics of the Makita BVR450Z vibrator

ParameterMeaning
Typedeep
Nutrition18 V, 3 Ah
Vibration frequency13000 vibrations/min
Flexible shaft length1,2
Vibrating tip diameter25 mm
Dimensions1483x93x250 mm
Weight3.7 kg

By tradition, we offer you to look at a short review of a similar model to get a complete picture of the Makita BVR450Z vibrator.

Grost VGB 4000 W – from 17,000 rub.

A review of concrete vibrators would be incomplete if we ignored such an autonomous solution as the Grost VGB 4000 W. This is a gas drive supplied without a flexible shaft and a mace, the cost of which will be another 5 to 7 thousand rubles.
depending on their size. Those. for a maximum of 25 thousand rubles. You can get full-fledged equipment for working in conditions of lack of power supply. Although more often it is purchased for convenience, because in this case there is no need for a long extension cord or the use of electric generators. If anyone is interested, Grost is another good China with Russian roots. A simple device, high power and durability - what more do you need from quality equipment?! Basic characteristics of Grost VGB 4000 W

ParameterMeaning
Typedeep
Power4000 W
Nutritionpetrol
Vibration frequency3600 vibrations/min
Flexible shaft length(3/4/6 m)*
Vibrating tip diameter(38/50 mm)*
Dimensions550x410x430 mm
Weight21.2 kg

*optional.

CHAMPION CVG424 – from 13,000 rub.

If the task is to purchase not an electric, but a gasoline vibrator, then you can save several thousand and buy CHAMPION CVG424 instead of model No. 9.
This, again, is good China, but with roots in the USA. A good compact model, which also comes without a shaft and tip (+5...8 thousand rubles). The frame is made of durable steel, has a reliable base and protects the powerful engine from damage during transportation. Features of the CHAMPION CVG424 vibrator

ParameterMeaning
Typedeep
Power4000 W
Nutritionpetrol
Vibration frequency3600 vibrations/min
Flexible shaft length(4/6 m)*
Vibrating tip diameter(28/32/38/45/50/60/70 mm)*
Dimensions550x410x430 mm
Weight23.6 kg

*optional.

Editor's Choice

Traditionally, the editors give preference to several devices included in our review of the best equipment. The results are as follows:

  • if you need a portable and lightweight model that is not tied to the length of an extension cord, then you should take a closer look at the Makita BVR450Z ;
  • a classic and very convenient deep-well vibrator with an electric drive, which is also compact in size - Sturm CV7120 ;
  • excellent value for money, one of the best solutions among area vibrators - Krasny Mayak IV-98E ;
  • for work on construction sites not connected to the mains – CHAMPION CVG424 with petrol drive

Making a device from a drill

To make your own vibrator at home, you should find an old drill on the farm. You will need to turn the rotation into an oscillatory movement. Let us examine in more detail the principle of manufacturing the device.

Selecting the materials required for self-assembly of the vibrator

To obtain a vibrator, it is quite enough to use a drill, but its power should not be less than 1 kW. At the same time, you need to prepare a durable tip made of stainless steel, an eccentric nozzle and some other parts:

  • metal rod;
  • tube (preferably stainless steel);
  • bronze bushing;
  • a pair of bearings;
  • square rod;
  • reinforced hose;
  • speedometer cable

Tools and materials

To facilitate the manufacturing procedure, you need to stock up on the following tools:

Assembly sequence

The structure must be assembled according to a strictly defined scheme. First you need to take a stainless steel tube. Its length is 60 cm with a diameter of 4 cm. To obtain an internal rod, a good option would be a metal rod that can move sideways in the tube to create vibration. The prepared parts must be combined: drill a hole at one end of the rod to attach it to the device.

Two bearings will ensure that there is no friction between the rod and the tube. The rod itself is threaded into the tube, driving the bearings along its ends until they stop. These supports will be subject to serious load, which is why it is necessary to select the highest quality bearings. A sleeve is put on the second end of the rod so that it tightly covers the inner space of the tube.


Figure 3. Homemade vibrator for concrete

Manufacturing stages

Let's consider a step-by-step scheme for manufacturing a vibrating nozzle, since it is the main element of the entire device:

  • first you need to cut a round steel rod in half with a grinder;
  • then the resulting sections need to be welded on different sides of the rectangular rod;
  • to ensure unhindered rotation, it is necessary to install rolling bearings at the ends of round bars;
  • thread the resulting structure into a metal tube;
  • Use a grinder to cut the round rod flush with the pipe on either side;
  • cut out a cover from a metal plate that completely covers the working end of the resulting tip, and then weld it to it;
  • drill in the round rod extending outward from the tip a pair of holes necessary for connection with the shaft (the first along the central axis to a small depth of about 1.5 cm, the other, with a diameter of approximately 4 mm, strictly perpendicular to the first, placing it 7 mm further than the edge rod);
  • in the axial hole it is necessary to cut the thread necessary to screw in the clamping screw;
  • place the flexible speedometer cable inside the reinforced hose, having previously lubricated it with grease, leaving about 5 cm of outlet on the sides;
  • connect the vibrating tip securely to the shaft;
  • Pull the hose onto the vibrating pin and secure it securely with a clamp;
  • cut off the protruding end of the shaft, leaving a length sufficient for mounting in the electric drill chuck, so that only the cable rotates, leaving the hose motionless;
  • It is necessary to protect the vibrating tip with a plastic casing;
  • Connect the tool to the electrical network and finally check the functionality of the home-made device.
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