Manufacturing Process of Cube Ballast
Cube ballast is a 40 kg, steel-reinforced precast concrete block that holds solar panel mounting structures firmly in place on rooftops and open ground, with no drilling into the roof and no dug foundations. Gandhar Group makes the standard 40 kg cube, and other weights and sizes to order, for power DISCOMs, solar EPC companies, railways and contractors. The production process includes the following key stages:
Moulds (cube-shaped) are thoroughly cleaned and coated with shuttering oil to ensure easy removal after casting.
Light steel reinforcement is placed inside each mould with the right cover, so the finished cube resists cracking and chipping.
Concrete is prepared using cement, fine aggregates, coarse aggregates, and water in the specified ratio to achieve the required strength.
The freshly mixed concrete is poured into the cube moulds uniformly.
Concrete is compacted using needle vibrators or table vibrators to remove air voids and ensure dense and uniform structure.
The top surface is levelled and finished smoothly using hand tools to maintain proper cube dimensions.
The filled moulds are kept undisturbed for initial setting under controlled conditions.
After 24-48 hours, cubes are carefully removed from the moulds once sufficient initial strength is achieved.
The cubes are cured by water immersion or regular sprinkling for 7-14 days to achieve desired strength and durability as per IS standards.
Each cube is checked for:
• Dimensions
• surface finish
• cracks or honeycombing defects
Cured cube ballasts are stacked properly in the yard with spacing to avoid damage.
Finished cube ballasts are transported to site and stacked ready for placing under solar mounting structures or use as counterweights.
Standard 40 kg cube
A uniform 40 kg cube, easy to carry by hand on a rooftop and quick to place in rows under solar mounting rails.
Steel reinforced
Light steel reinforcement inside keeps each cube from cracking or chipping in handling, transport and years outdoors.
Made to order
Other weights and dimensions are cast to the customer's drawing, for solar, railway and power line projects.
Throughout every stage, Gandhar Group remains dedicated to quality assurance and process efficiency, delivering reliable cube ballast for solar and infrastructure projects.