The manufacturer consults with the customer to determine factors such as the total safe size, desired shape, and location of the door. Once this process of requirement collection is over, then the customer will sign off on the selection. Manufacturer would then configure the right equipment needed to construct the safe walls, reinforced, propriety or completely steel. Setting the wall panels is hence the next significant step in the process. The setting of the wall panels is called the molding step in manufacturing. The molding step will also result in the strength setting and more. Here in the molding of the safe walls, the manufacturer and client might require it to be done in-situ or might be done at a manufacturer place and then installed.
Unlike regular concrete used in construction, the concrete for safes is so thick that it cannot be poured. The slump value for concrete indicates the consistency of the concrete. Usually, in the case of safe wall construction, the manufacturer will be required to ensure that there is zero slump. Propriety mixtures used in the case of concrete would make it have a much quicker drying process which will ensure the zero slump state. This form of mix dries in around 6-12 hours whereas normal concrete would require anywhere from 3-4 days.
In the safe wall molding step, the mixture is poured into the molds. Where concrete might be used with reinforcement steel, it is at this point that workers place the reinforcement steel rods in place. The molds might be gently vibrated during this process to ensure there are no air pockets at this point. Once the mold process is set, then the edges would be smoothened out with a trowel while the concrete is allowed to set in the panels and harden.
Doors of safe might be made of special molding panels unlike that of the walls. This is to ensure that the opening and more is proper. Hole for the lock might be used or the material for the door alone could be pure stainless steel cladding in addition to the concrete setting. This manufacturing process step is done differently based on requirement. Studies note that some of the manufacturers would actually end up using a complete steel cladding. They would pour the concrete directly into the cladding and this will ensure that the door is just as strengthened. Sometimes, people might also use a regular mold instead and then pace a steel plate on top so as to ensure that resistance is on the outside. Door manufacturing is also more intricate given that there might be a necessity to place dual combination locks as well and their installations could hence vary.