Today, one of the main trends for start-up entrepreneurs has become the organization of mini-productions. Expanded clay concrete blocks are one of the most demanded products on the market, which is used in construction. This material is ordered by both individuals and construction companies. Its production does not require expensive equipment and special knowledge. Partially, machines for the manufacture of expanded clay concrete blocks can be made at home, and the price of components for this purpose is quite low.
If we talk about the professional level of a business with an average supply of building materials, then you should prepare for significant expenses for renting premises for a workshop. If you purchase, then you can not be afraid of such restrictions, however, the turnover will differ significantly.
Advice: before purchasing equipment, enter into a preliminary sales agreement or find customers to whom you could sell finished goods. When opening a mini-production of expanded clay concrete blocks, it is the sale of products that becomes the key problem, since the threshold for entering this business is quite low, as is the case with. Thus, for those who have potential customers, everything is greatly simplified. A preliminary assessment of the market can significantly simplify the further development of the business.
Technology for the production of expanded clay concrete blocks
All expanded clay concrete blocks are a mixture of sand, expanded clay, cement, plasticizer and water. Depending on the expected proportions, various types of expanded clay concrete will be produced:
- Heat-insulating block;
- Structural block;
- Structural and heat-insulating block.
The technology itself is distinguished by some changes in the composition. If you add more cement, you can get a structural block. Its scope is to create bearing walls, since such expanded clay blocks are characterized by high strength and rigidity. If it is necessary to ensure the preservation of heat in the room, then structural and heat-insulating types of products will be more preferable. This type includes the positive qualities of other types and is created using initial products in a volume fraction of 30% sand, 60% expanded clay, 10% cement, and 8% water. Thermal insulation blocks, as the name implies, are distinguished by an emphasis on heat retention, but this negatively affects their strength characteristics.
First step technological process is to create a mixture. For this, a concrete mixer is used. Having picked up the components in the required proportions, we send them to the mixer. It should be noted right away that it is desirable to use expanded clay sand, and expanded clay itself should consist of fragments of a fine fraction, the size of which does not exceed 10 mm. The additive that can be used as a plasticizer is the usual building materials Portland cement. For the manufacture of expanded clay concrete blocks, the M500 brand is suitable.
It should be noted that water is poured directly into the concrete mixer first. Then expanded clay is poured, after which sand is introduced without stopping mixing. Upon reaching the homogeneity of the composition, cement is introduced, and after it a plasticizer. It is important that all components are evenly mixed. The final mixture should contain a moderate amount of moisture, and when squeezed by hand, molded. If the shape is not preserved after mechanical action, the moisture content of the mixture is excessive.
After creating the finished mixture, you need to pour it into the mold. To obtain a better packing of fine particles, the mold blocks are preliminarily placed on a vibrating machine. The resulting expanded clay concrete mixture is loaded into the metal matrix. After filling the container, you need to gradually increase the power of the vibrating machine. If necessary, the mixture is added to the mold, and its excess is removed using a leveler. The result is a block of a given shape without voids and irregularities on the surface of the product. The molds are then sent to dry.
This step requires 2 days minimum. To dry expanded clay concrete blocks, it is necessary to place the molds in a special room, the temperature of which will be maintained at a stable level. In fact, it is necessary to ensure that this chamber is heated up to 50-60 degrees. After two days, the dried block can be removed from the mold. After that, it is advisable to leave it in the open air. This will take another 10-14 days. Only then will the block completely harden and be used as a building material.
Creation of a workshop for the production of expanded clay concrete blocks
One of the most important points in the organization of the production of expanded clay concrete blocks is the choice of a suitable room. It should be big enough to fit everything. necessary equipment. In addition, it will need to organize a separate space for storing finished products, and it is also desirable to have a special room reserved for primary drying.
There must be a room in which the staff will be. Dressing and dining must be done outside of the main production area. We also need a room to accommodate a security system, general control of the process of the line functioning. There should be bathrooms, a doctor's office to provide emergency assistance in case of injury to workers. In addition, it is desirable to have a separate secure parking.
It is desirable to place all zones of different functionality in separate rooms. Each of them must be provided with a heating system. Since winters in Russia are quite cold, it will be extremely difficult to do without a good heating system. Another important point is the presence of water supply with sewerage. This is extremely necessary not only to ensure comfortable working conditions, but also to obtain a source of water, which is part of expanded clay concrete mix. Also, you can not do without electricity, which ensures the operation of all machines and the desired level of lighting.
Separately, it is worth stopping at the drying room. It can be quite a compact room - it all depends on the capacity of the production line. The room should be airtight, which will significantly reduce electricity costs. In addition interior decoration must be fireproof. All of this comes at a cost, so find out to help reduce the credit burden on your business.
Advice: To save money, you can use fire-resistant materials. For example, take a special plaster or drywall. This will place heating elements against the walls without fear of accidentally starting a fire.
It will be good to organize a dining room or a room in which workers can safely eat. This is especially important for cases in which more than a hundred people are involved in production. For those who intend to open a fairly large business for the production of expanded clay concrete blocks, about 30 people will need to be involved in each shift, which leads to the need for a canteen with an area of at least 12 sq.m.
The dressing room should also contain enough space to accommodate employees' personal lockers. It is also important to separate them into male and female. Ensuring the security system and training for the security worker of a separate room also play an important role. Installing surveillance cameras in the workshop will not require a lot of money, but it will help to avoid situations associated with the theft of building materials. It is desirable to provide similar measures for the room of finished blocks, as well as the checkpoint and parking.
Equipment for expanded clay concrete blocks - price
The minimum set consists of a concrete mixer and a vibrating machine. Already with these two devices, it is possible to produce expanded clay concrete blocks. A concrete mixer should be chosen with a large volume to ensure maximum loading of existing forms. The cost of concrete mixers right size is 10-15 thousand rubles. This allows, if expansion is necessary, to purchase a new concrete mixer to ensure the operation of additional vibrating machines. The latter are approximately in the same price category.
In this way, minimum expenses for equipment will amount to about 20-30 thousand rubles. This will allow you to produce about 200 blocks per shift and is great for starting with a small capital. Two workers will be able to serve one vibrating machine and a concrete mixer. The technology is even more simple, so it is worth paying attention to if the cost of creating a line for the production of expanded clay concrete blocks seems high.
Advice: pay attention to the vibrator and the power supply required for it, voltage. The power supply can be from 220 V or 360 V. Make sure that the power supply conditions are in industrial premises suitable for a particular occasion. To provide more convenience when removing the finished product from the mold, a metal plate must be placed on the bottom of the matrix, with which the block will be sent for drying.
It is worth understanding what volumes of production are involved when working with one vibrating machine. To dry 200 blocks, a fairly spacious chamber is required, and given that the products will remain there for two days, it is worth providing space for at least 600 blocks. In fact, using three machines in a few days, you can produce enough building material to build the outer wall frame of a house with an area of 100 "squares".
There are also quite advanced automated lines for the production of expanded clay concrete blocks on the market. The average cost of quality products in this segment is 500 thousand rubles. You can speed up the work by automatically feeding the mixture into the matrix of the vibrating machine. It allows to produce about 1.2 thousand blocks per shift.
The cost of 6 machines and concrete mixers that can provide a similar level of productivity will be at least 120 thousand rubles, which is significantly cheaper, but requires more workers for maintenance and a large workshop area. It would be wise to start with the usual pair of concrete mixer-vibrating machines, and then gradually expand. As a result, you can save up for an automated line or sell a few used production pairs to free up space on the shop floor and reduce capital costs for new equipment.
Transportation of expanded clay concrete blocks to the drying chamber from vibrating machines can be done using a trolley. It will also be used to send the blocks to the warehouse after two days of intensive removal of moisture. As you can see, the work does not require qualified personnel, which opens up wide employment opportunities, which means that it will allow you to get by with a fairly low wage. In some cases, with an acute shortage of funds, you can work independently, and after the start of sales, hire workers. The production of expanded clay concrete blocks can be considered as one of the types of business with a low entry threshold.
The only important requirement for applicants for workplace in the case of this direction of production is the absence of bad habits and addictions. This is especially critical for those who, for whatever reason, do not place cameras in the shops and do not hire security to control the integrity of workers. The level of education in the production of expanded clay concrete blocks does not play a big role.
If you are recruiting staff to work with an automated line, then it is advisable to find at least one experienced operator who will not necessarily work for you, but at least be able to teach workers the intricacies of operating expensive machines. As a rule, people around the age of 35 work on such lines, so it is very important to organize the transfer of experience to younger beginners.
Advice: the practice of recruiting students has proven itself well. In this case, one machine is serviced by both professionals and beginners. After full training, you can transfer the latter to a new line when expanding production. Thus, it will be possible to avoid malfunctions and reduce the number of emergency stops and machine downtime.
In addition to workers to maintain the equipment, it is advisable to hire several people to control the quality of the produced blocks. They will have to inspect each unit for mechanical damage, as well as other defects. For said work women will be the most suitable, since they are more perseverant and accurate. Another important point is the delivery of products to the consumer. If at the initial stage you can do without your own delivery service, then with a fairly active work with customers and ensuring a large turnover, it will be required.
For this purpose, a small truck that could already be in operation is suitable. It will require 2 loaders, as well as a driver with the right to drive a car of the appropriate category and some work experience. For loaders, physical endurance and strength are important. To communicate with customers, you can create a mini call center and fill it with operators to answer the most frequent questions of potential customers. It is important that they understand the topic.
Payback of equipment for the production of expanded clay concrete blocks
First of all, it is important to remember that for a fairly large business, equipment will not be the only expense item. Renting a large space can be a significant investment. If we talk about the minimum indicators, then 1 square meter production and storage space can be rented for approximately 6-8 thousand rubles.
The workshop will require about 100 sq.m, for the drying room - 50 sq.m, for the warehouse - 100 sq.m. Plus, some space will be occupied by a bathroom, a dining room and a locker room. It is worth proceeding from the need for about 300 sq.m. Thus, at a minimum, this will amount to 180 thousand rubles per year, that is, the monthly payment is 15 thousand rubles. On the indicated territory, 3 pairs of concrete mixers and vibrating machines can be freely placed, that is, one-time costs directly for equipment for the manufacture of expanded clay concrete blocks will amount to 60 thousand rubles.
Additional equipment for the premises will cost another 200-300 thousand rubles. That is, the total costs will be at the level of 500-550 thousand rubles. You will also need to purchase raw materials. This is about 200 thousand rubles. Three pairs of mixers and vibrating machines will make it possible to produce about 600 blocks of expanded clay concrete during 1 shift. The price of one unit of the finished product is approximately 18-22 rubles, of which about half is profit. At a cost of 20 rubles per shift, products will be manufactured in the amount of 12 thousand rubles, which for 20 working days a month will give an income of 240 thousand rubles.
Approximately 120,000 rubles will be spent on salaries, and another 15,000 rubles on rent. The rest will be 105 thousand rubles. Based on the cost of 700 thousand, equipment for the production of expanded clay concrete blocks will pay off in 6.5 months. If, however, shifts are organized so that there are 30 working days due to staff expansion, then the payback period will decrease.
The nuances of selling expanded clay concrete blocks
Each product must be sold to make a profit. The process of implementing expanded clay concrete blocks is not as simple as it might seem. The bottom line is that in some areas there is a fairly high competition. Even if the niche was free at the time of opening the business, there is no guarantee that similar lines will not appear in the near future.
The marketing strategy for this business begins precisely with organizing your own delivery service. This point can be emphasized in advertising, because often construction companies ready to overpay a little, but not waste time looking for a transport that can deliver the blocks to the place of work. In the domestic car market, you can find a UAZ with sides for 450-500 thousand rubles, the carrying capacity of which exceeds 1 ton.
Advice A: In the case of limited capital, an agreement can be made with a local trucking company. Ideally, this will allow you to spend less money than at the standard rate as a regular customer. It is important to know if there are free cars in order not to give the client false hopes when the partner cargo taxi is loaded to the maximum.
Continuing the topic of partnership, it is very profitable to conclude an agreement with a developer company for the regular supply of expanded clay concrete blocks. Many go for it, because it is much more profitable to buy materials at wholesale prices. For the manufacturer, this guarantees some stable sales volume. The discount for a regular customer is usually fixed at a level of 5-10%, which allows satisfying both parties.
Save the article in 2 clicks:
Based on all the data on the production of expanded clay concrete blocks, we can conclude that this is a fairly profitable and profitable business, which is perfect even for beginner entrepreneurs. Note that the calculation of the cost of rent was made on the basis of the offer in Moscow, that is, in the regions, a smaller amount of funds will be needed to open such a business. If you need a faster payback, then evaluate. Also interesting option is an . Small investments and a wide scope of application allow you to get high profits from the sale of this product.
In contact with
Expanded clay concrete blocks are a building material used for the construction of walls of residential and industrial buildings. Their widespread use began relatively recently, but they have already gained popularity among most builders.
The process of manufacturing expanded clay blocks can be done both at the factory and at home with your own hands. But in the second case, the quality of manufactured products will be significantly lower.
According to the method of manufacture and characteristics, they are similar to pure concrete blocks, with the difference that expanded clay is used as a heavy filler, and not crushed stone. Due to the lightness of expanded clay, the blocks are much lighter than classic concrete ones.
1 Benefits of using expanded clay concrete blocks
Expanded clay blocks have such an excellent property as incombustibility. This is true due to the fact that expanded clay cannot catch fire or melt. At high temperatures it can only crack and collapse. It is the elimination of the need for additional fire supervision that makes such blocks popular in all types of construction.
Expanded clay demonstrates high performance not only at high, but also at low temperatures. When building in a cold northern climate, expanded clay concrete blocks become an indispensable tool. During frequent temperature changes, expanded clay can withstand about 50 freeze and thaw cycles.
Using expanded clay concrete, you can be sure of keeping the heat inside the apartment. Accumulation during the day of solar energy, together with the property of slow heat release during external environment made expanded clay an excellent material for the construction of civil buildings.
Expanded clay houses have the ability to "breathe", thereby maintaining optimal temperature indicators in the room.
Expanded clay blocks do an excellent job of isolating street noise, and the need to install an additional soundproofing system disappears by itself.
Thus, we can distinguish the following main advantages of the production of expanded clay concrete blocks:
- reduced weight compared to concrete, high strength;
- thermal insulation properties;
- resistance to aggressive chemical environments;
- the speed of building walls using this material;
- frost resistance;
- complete environmental friendliness of production and further use in construction.
1.1 Manufacturing technology of expanded clay blocks
The main material for the production of such blocks is expanded clay. It is obtained by high-temperature processing of clay or shale. Other required elements: water, cement, sand.
Sometimes various plasticizers are added in order to reduce water consumption and increase the elasticity of the mixture. Most often it acts as a plasticizer. liquid soap or glue.
Depending on the proportions of the components of the expanded clay mixture, made block can have a variety of characteristics. The most common types in the manufacture of expanded clay blocks are:
- structural;
- structural and heat-insulating;
- heat-insulating.
The first option, a structural block, can be obtained by increasing the proportion of cement in the total mass of the composition. The production of such blocks is rational for the construction of multi-storey residential buildings, where rigidity and strength of the supporting structures are required.
If in the first place is the preservation of heat in the room, then you should choose the proportion in this variant: 60% expanded clay sand, 30% ordinary river or sea sand, 10% cement and 8% water.
Now in detail about the manufacturing steps. First of all, it is necessary to form a claydite-concrete mixture in the required proportions. The diameter of all fractions should not exceed 10 millimeters. Cement is recommended to use brand M400. All components are thoroughly mixed in a concrete mixer. The procedure for pouring the mixture into the concrete mixer is as follows:
- Water.
- Expanded clay.
- Cement.
- Sand.
The next mandatory process is the formation of blocks. In a special niche on the vibrating machine, a mold is installed into which the concrete mixture is poured. After the compaction of the mold is completed, the excess mixture is removed from the surface of the mold, and then the mold itself is sent for drying.
The first section of drying takes place within 2 days in steel plates, at a maintained temperature of 50-60 degrees. After this period, the form is taken out into the open air and undergoes a second drying period lasting 7-10 days. All these operations can be done with your own hands, without purchasing expensive equipment.
2 Required equipment
To fully ensure the production technology, the manufacture of expanded clay concrete blocks requires complete set equipment. To prepare the concrete mix, concrete mixers are required - large containers placed on a rotating axis. Their main difference is the capacity (displacement) and the number of revolutions per minute.
A manual vibrating machine is an ideal machine for the production of blocks with your own hands, as well as a machine for the production of arbolite blocks. They are small in size, which makes it possible to carry out production at home.
The vibrator is fixed on the surface of the body and oscillates, contributing to the distribution of the mixture in the form evenly and without lumps. Manual machines can have stationary and removable void formers. Removable void formers allow you to configure the block type at your discretion.
The vibrating table is a machine with a pallet 3 mm thick with sides. It is on the pallet that the molds are compacted by vibration. The work behind it is simple and easy to do with your own hands, it is possible to make about 6 forms at a time.
Due to the location of the vibrator at the bottom of the pallet, the vibrations are distributed evenly over the entire surface, which has a positive effect on the quality of the output product.
The vibropress is already a much more powerful and overall machine, which is used in the production of expanded clay blocks on an industrial scale. It has a hydraulic drive that exerts several tons of effort to compact products.
The void formers are located on special ramps and are pressed into the mold as needed.
On pallets, the final molding of the blocks takes place. The vibropress eliminates do-it-yourself work at all stages of production.
2.1 Machine Rifey-Universal M
The Rifey vibrating machine is excellent for the manufacture of concrete products from rigid mixtures with a filler such as expanded clay, using the volumetric pressing method. The maximum dimensions of molded products are 780 × 390x230 millimeters. For everybody separate species blocks must have a separate matrix.
Using the Rifey machine, you can produce the following building products:
- wall blocks, cinder blocks, expanded clay blocks;
- borders;
- facing stones;
- paving slabs.
In the CIS countries and Russia, this press is used primarily to create do-it-yourself expanded clay building materials, and only then you can use this machine to produce paving slabs.
The complete set of the machine consists of a mixture preparation module, which includes a 300-liter mixer and a conveyor that sends the mixture to the vibropress. And also from a forming module with a vibropress directly, a pump, a control panel, a drive and a cassette for feeding pallets.
The delivery can be supplemented with a punch-die assembly intended for the production special forms wall stone.
Productivity and quality of production do not leave equal machine Rifey in the market of vibropresses. Constructive decisions make it possible to re-equip the press for the production of other products in just an hour, by replacing the punches-matrices. Reliability, ease of maintenance, repair and maintenance minimizes costs in the production of expanded clay blocks.
2.2 Manufacturing technology of a machine for the production of expanded clay concrete blocks with your own hands (video)
Expanded clay blocks are a concrete wall material used for building walls of industrial and civil structures.
Expanded clay blocks are similar in properties to concrete blocks, but in their production, not crushed stone, but expanded clay is used. This material is lighter than crushed stone, so the blocks and the building structure itself are much lighter. Expanded clay is obtained from clay. It is porous and has good thermal insulation.
Expanded clay blocks have a lot of advantages: lightness, strength, frost resistance. They are widely used in the construction of various facilities and guarantee a reduction in the load on the foundation.
The expanded clay concrete block production business is a promising and fast-paying business that does not require significant costs.
This is your reliable business. Due to the relative simplicity of the technological process and the small amount of equipment used, writing a business plan is not so difficult.
The following advantages of these blocks stand out:
- low weight (reduces the load on the foundation by 2.5 times compared to brick);
- high strength and thermal insulation (heat loss is reduced by 75%);
- moisture and chemical resistance, breathability;
- construction speed (the cost of work is reduced by 30-40%);
- environmental friendliness, strict compliance of the constructed walls with sanitary standards and requirements;
- no need for additional insulation and wall shrinkage;
- frost resistance is not lower than the level of a brick (50 cycles).
Thus, this material is suitable for the manufacture of garages, utility rooms or agricultural buildings. It is also suitable for the construction of residential cottages.
Resistance to rotting and burning, the ability of the material to "breathe", due to the porous structure, in many cases makes it an indispensable material. Together with durability and reliability, expanded clay concrete block becomes practically best material for construction in a variety of conditions.
Prices for equipment and calculations are given on average for Russia.
Back to index
Consumers and distribution channels
The main consumers of expanded clay concrete blocks are individuals and industrial enterprises, construction organizations, farms and other organizations. Business has long appreciated their advantages, and expanded clay concrete blocks successfully compete with other building materials.
Finished products are sold through two main distribution channels:
- construction shops and wholesale construction depots;
- mass media (ads, poster advertising, Internet).
The popularity of this material is so high that it does not require the creation of a particularly complex implementation plan. The expanded clay concrete block business is able to generate a steady income, as there is a constant demand for cheap and affordable building materials. The production of this material is year-round, but the business plan must take into account seasonal demand factors.
Back to index
The production process includes the following steps.
- Mixing of components: expanded clay, cement, sand, water (the composition is determined individually according to GOST and TU).
- Molding (giving the necessary shapes and sizes).
- Hardening with vibropress.
- Drying.
- Packing for storage and transportation.
The production technology involves the process of vibrocompression of several components. The preparation of the solution is a critical step and must exclude errors. The mortar uses cement grade M500 or M400. Sometimes a natural stone or tile adhesive is added to give the product a glossy finish.
The components are mixed in certain proportions, then they go to molding, after which they acquire the necessary sizes and shapes. Their hardening is provided by special equipment: a vibropress and a hardening chamber. After simple manipulations, the hardened product is dried and placed on pallets.
The finished block hardens within a day. It takes 7 days to receive a completely finished block.
Back to index
Equipment and conditions for the production of expanded clay concrete blocks
To organize the production process for the production of expanded clay blocks, the following equipment and conditions are required:
- heated, ventilated room with electricity and a flat floor for work throughout the year;
- open area for drying and storage of products;
- concrete mixer;
- vibropress (vibration machine).
The vibropress is the main equipment in the production of expanded clay blocks.
Interchangeable molds and a machine for the production of expanded clay blocks are installed on the vibrating table. The mechanism is very simple and reliable. Designs are usually designed for one or more forms. They are low cost and high performance.
Machines equipped with fixed block mold - more than complex structures. Work on them is easier, and the share of manual labor is minimized. Vibration enters the mold. The release punch guarantees a perfectly even and smooth surface of the block.
At first, to save money, you can prepare the mixture by hand. With the expansion of production, you can switch to the use of an electric concrete mixer. Most of these devices have a drum with powerful internal blades, their output volume is from 125 liters.
When choosing machines, pay attention to modern technological innovations. For example, you can purchase a detachable form with a locking connection, which makes it possible to remove the block without damaging its surface.
Most modern vibrating machines are very efficient and can produce up to 1,000 blocks in 1 working day (8 hours of work). The machine can be operated by 2 workers. The payback period of funds invested in the purchase of a machine is several months.
In addition to the production of expanded clay blocks, this equipment is used for the production of products from slag, sawdust, crushed stone and other substances. The vibropress operates on a voltage of 220 and 380 volts. Power averages 3.1 kW.
The machine is compact in size (usually 230-11-165 cm) and weighs about 500 kg. It can be placed in a small room.
We offer several ways to complete the technological line for the production of expanded clay concrete blocks. A business plan may have several options, since production can be differentiated depending on the type of equipment used.
Method number 1. Economical
- Vibrating table EV-346 - 35,400 rubles.
- Molding pallets - 4000 rubles / piece.
Alternative option - Vibropressing plant STROM-press
Productivity - up to 600 expanded clay blocks.
One cycle ensures the production of 2 blocks.
Price - 75,000 rubles.
The vibrating press produces much higher quality blocks compared to the vibrating table.
Method number 2. Turnkey line. KVADR 1SO2
Main kit:
- Vibro-press KVADR 1SO2.
- Concrete mixer KVADR BP2G-375 or BP1V-375.
- Installation platform.
- Shaping equipment.
Productivity per shift - 10 cubic meters.
The required area is 120 square meters.
The height of the room is 5 meters.
Personnel - 1 worker.
Price - 1,215,813 rubles.
Method number 3. own line
- Concrete mixer SGS-M245 - 98,000 rubles.
- Vibropress K-01.
- Technological pallets - 2 pieces.
- Hydroelectric station with hydrodistributing and RVD.
Specifications (business plan of production):
Productivity makes 110 pieces/hour (1.6 cubic meters) - for 1 working shift 12.8 cubic meters.
Dimensions - 800*840*1350 mm.
Weight - 420 kg.
Personnel - 3 employees.
The cost is 248,000 rubles.
Additionally required:
- roller table (for receiving products) - 5900 rubles;
- form kit - 50,220 rubles.
In total, the costs for the second version of the line are 402,120 rubles.
With almost the same performance, the costs for the third option are much lower. Therefore, we will consider them basic when planning the production of expanded clay concrete blocks.
For the third method, you can purchase a model of the VP5M vibropress (lower by 40,000 rubles). On average, the payback period for the production of expanded clay blocks is 6 months.
Developers began to use it with pleasure, as they were convinced of the manufacturability, reliability and practicality of this material. This article will talk about what expanded clay concrete blocks are and how to make them yourself, what are their features and advantages over other building materials.
You will learn about the production technology, how it is possible to make expanded clay concrete blocks with your own hands, is this process worth the time and effort.
Expanded clay concrete is lightweight, which allows you to create durable housing of a fairly presentable appearance, even on an insignificant foundation.
Expanded clay concrete- the only one with the most promising modern materials for construction. Its properties in terms of the speed of construction of various objects and the cost-effectiveness of its use significantly exceed the qualities of other materials.
Expanded clay structures are made exclusively from natural ingredients, and for this reason do not emit toxic substances into environment. If you believe the reviews of those who built the house from expanded clay concrete blocks, they claim that very comfortable climatic conditions for living are established in the room.
Note. High-quality expanded clay concrete blocks have a density of 600 to 1800 kg/m3.
Production of expanded clay concrete blocks
Expanded clay concrete has unique properties determined by the peculiarity of their manufacture. Expanded clay is taken as a basis - an environmentally friendly material.
It has pores resembling a sponge in structure, in which there is a specially fired clay, which acquires the texture of a frozen foam. As a result, this material is very light and durable. Cement is used as a binder.
The strength and ability to retain heat depends on correct proportions mixtures. The more granules in the mixture, the more fragile the block becomes, but at the same time, the warmer, and vice versa.
Varieties of expanded clay concrete blocks
Expanded clay structures according to their own physical and technological data and purpose are divided into:
Density of heat-insulating expanded clay concrete blocks is the lowest. This type of expanded clay is made in a special way that promotes the formation of large pores. The density of such granules is 150-200 kg/m3.
Structural expanded clay bears resemblance to natural stone, which is why the walls of a house made of such material will be extremely dense. A significant advantage of expanded clay concrete over other building materials is the price.
The pace of installation of walls made of expanded clay concrete is 4 times faster when compared with brick buildings. In addition, when building houses from this material, 2 times less mortar is used, again when compared with brick.
The shape of expanded clay concrete blocks is complex, it has many voids-slits that improve heat retention in the house.
desire to have private house pushes people to look for cheap materials for construction. Expanded clay concrete blocks are just the material that is increasingly popular with developers.
The main feature of expanded clay concrete is that, in addition to the low cost on the market, it can be made by hand. We propose to consider the main nuances and tricks, as well as the composition of expanded clay concrete blocks in accordance with GOST.
What do you need to get started?
The manufacturing process is simple, the main thing is to adhere to the proportional ratio of components - 1:3:8. Water is added at the rate of 200 liters per 1 m3.
materials
Tools
Manual machine for vibropressing
You can buy it in stores where they sell everything for construction. approximate cost 7 - 10 thousand rubles. You can also order from manufacturers. The design already has special molds for casting blocks. Also, the machine can be made with your own hands from an old engine and a metal worktop.
If you have the required number of molds and an extra pair of hands, about 150 expanded clay concrete blocks can be made per day.
In one working cycle, the machine produces 1 - 4 blocks. And if you assemble a team of several workers, the number can increase by about 2 times. Blocks can be made without equipment, the main thing is to choose a capacious container for mixing and pour into molds.
The molds for expanded clay concrete blocks themselves can be made of metal, plastic, wood (fasten with metal corners, sheathe them inside). To form voids in blocks, some craftsmen use plastic bottles filled with water.
When mixing the solution, the exact amount of water is taken first. Sand, cement and expanded clay, sand are mixed, and then liquid substances (water, plasticizers) are introduced. In appearance, the mixture should turn out like softened plasticine.
Drying of expanded clay concrete
The final stage in the manufacture of blocks of expanded clay concrete is the drying of the finished product.
This takes approximately 2 days. In wet weather, the rocks increase.
Then the blocks are stacked on pallets in a row of 3-4 pieces. The finished blocks should not be exposed to sunlight and rain, it is better to keep them under a canopy. They are allowed to work in 1-1.5 weeks after production.
by the most the best option is drying for a month. Before laying, the blocks are cleaned of roughness and irregularities.
The cost of expanded clay concrete blocks do it yourself
According to some estimates, the approximate price of expanded clay concrete blocks will be about 20 rubles. For comparison, the price of finished ones is about 80 rubles. Savings, as they say on the face.
The rapid development of advanced technologies has led to the emergence of unique building materials, including expanded clay concrete. This type of concrete complies with all GOST 6133-99 standards and is an indispensable solution for the construction of all kinds of buildings. The proportions of expanded clay concrete for blocks imply the introduction of expanded clay, not crushed stone.
Description and characteristics
The material is characterized by low weight and excellent performance characteristics that are characteristic of concrete structures. Due to its low thermal conductivity, it can be used for arranging wall structures and ceilings.
The characteristics of expanded clay concrete blocks are as follows:
- Strength - 35-150 kg per cubic centimeter.
- Density - 700−1500 kg per cubic meter.
- Thermal conductivity - 0.15−0.45 W / mGrad.
- Frost resistance - 50−200 cycles.
- Shrinkage - 0% mm/m.
- Moisture absorption - 50%.
In the manufacture of expanded clay concrete with your own hands, the proportions are selected taking into account the required consistency and features of the building. To create blocks with different densities, it is necessary to calculate the correct ratio of the plasticizer, which gives the composition elastic properties, as well as other components that determine a number of key characteristics of expanded clay concrete.
Externally, expanded clay concrete is characterized by a cellular structure with different size pores (it is determined by the firing mode of the main filler). Depending on the porosity, three types of material can be distinguished: coarse-porous, porous, and also dense.
Concerning operational properties and advantages, they directly depend on the homogeneity of the structure of the concrete mixture. Normative strength indicators are determined by the correctly chosen ratio of expanded clay gravel with fine and coarse fractions. If the material will be used as the basis for the construction of structures, it must be additionally equipped with reinforcement, which will increase strength.
In most cases, expanded clay concrete is used to form enclosing and heat-insulating layers in multilayer building forms. The characteristics and serviceability of the final composition depend on the selected proportions and the correct ratio of the components. It is important to understand that the recipe for expanded clay concrete for flooring and building blocks varies significantly.
When laying the screed, the type of surface must be taken into account, as it determines the composition of the mixture. The optimal proportion for the manufacture of a screed with a height of 30 mm per 1 m² is as follows: 40 kg of a mixture of sand concrete grade M300 and 35 kg of expanded clay gravel.
Advantages and disadvantages of the screed
Expanded clay concrete screeds guarantee high reliability of the floor base, as well as its resistance to moisture, air and negative temperatures. Among key benefits design should highlight the following points:
But, in addition to the advantages, the claydite-concrete screed also has disadvantages. First of all, this is a significant rise in the height of the floor, as well as the need to polish the floor surface after the composition dries.
Production technology
The technology for the production of expanded clay concrete blocks is particularly simple and affordable, which makes it particularly popular among a wide audience of builders. Such material can be used for the construction of a small residential or commercial building in a country house or a plot near the house, the construction of premises on insufficient good ground and many other household tasks.
The high popularity of the technology is due to the excellent properties of the material and the affordable cost of production. It can be made without any special difficulties directly on a private site, without using sophisticated equipment and the help of specialists.
Blocks of expanded clay concrete can be both hollow and full-bodied. At the same time, regardless of the form, they include the main filler - expanded clay gravel. Solid structures are in demand for arranging the foundation and cladding of external walls, while hollow structures play the role of soundproof and heat-insulating partitions between the internal and external walls of the building.
When using porous technology, it is possible to increase the bearing capacity of the foundation and wall structures of the room. At the same time, the main advantage of using such concrete is a significant reduction in the cost of construction work, a long service life of the product and a low weight of expanded clay concrete.
Composition and proportions
Without a doubt, claydite concrete is currently one of the most popular building materials. The composition per 1 m³ should include the following components:
- cement mixture.
- Sand.
- Fine expanded clay, which is created on the basis of natural raw materials.
- Water without all sorts of impurities and chemicals. It should be noted that in no case should water with an acidity below pH 4 be used to dilute the mixture. sea water, as it can lead to the appearance of a white coating.
Also, the composition of expanded clay concrete (proportions per 1 m³ are calculated in advance at the construction site) may include several additional additives, such as sawdust, wood ash and plasticizers.
In order for the future building mixture to meet all the requirements, You must adhere to the following guidelines and rules:
- You can increase the elastic properties with the help of quartz sand.
- To make the future block moisture resistant, expanded clay gravel (without sand) must be added to its composition.
- Portland cement branded from M400 is characterized by excellent binding properties, so it is better to give preference to this particular model.
- The cement mixture has a positive effect on the strength characteristics of the structure, however, in the presence of this component, the weight of the product increases significantly.
- Provided that the future block will be subjected to heat treatment, it is better to use alite cement.
As for the density of raw materials, it directly depends on the components that are introduced into the composition of expanded clay concrete blocks. The proportions for a material with a normal density imply the introduction of large-fraction expanded clay. In most cases, such blocks are used to equip heat-insulating partitions.
If we are talking about the construction of load-bearing wall structures, it is advisable to use fine expanded clay. Too many small particles will make the block quite heavy, so experts recommend looking for a "golden mean" by mixing large and small "stones" for expanded clay concrete. The proportions per 1 m³ are determined by the type of work that is planned.
Before you start creating a mixture, you need to carefully study the recipe and pay attention to a few recommendations. This will avoid many difficulties in different stages production, as well as get a high quality product with the best features:
It is not difficult to make sure that the mixture is ready: to do this, you need to scoop up a homogeneous mass with a shovel and see if it spreads or not. If the slide begins to spread over the shovel, this indicates that the expanded clay concrete is too liquid. If the consistency is stable and not loose, then the required ratio of components has been achieved.
Depending on the design features, different grades of concrete are used for the manufacture of expanded clay blocks:
- M50 - suitable for the construction of partitions.
- M75 - is an indispensable element for the construction of load-bearing walls for industrial and residential facilities.
- M100 - are used in the construction of premises with a small number of storeys, insulation of enclosing structures and the arrangement of monolithic floor slabs and screeds.
- M150−200 - this brand of concrete is used for the construction of load-bearing structures and when creating wall blocks or panels. The material is distinguished by its ability to withstand strong temperature fluctuations and chemical attack.
- M200 - is a popular composition for creating light blocks and floors. The advantage of the material is resistance to moisture and chemicals.
Mixes of expanded clay blocks
As mentioned above, the proportions and recipe of the expanded clay concrete mixture depend on the characteristics of the project for which they are intended. For example, if you need to make high-quality blocks, it is better to follow this recipe:
- To begin with, one part of cement and 2-3 parts of sand are mixed.
- After obtaining a homogeneous mass, 0.9-1 part of water is added to the consistency.
- Then the composition is stirred again, and 5-6 parts of expanded clay are added to it.
If the filler is not moist enough, it is better to increase the volume of water. In the absence of good sand, you can use Peskobeton. In the manufacture of expanded clay concrete for the floor, one part of cement and one part of water, three parts of sand and two parts of expanded clay are mixed. For a wet CB screed, it is customary to use expanded clay gravel in the proportion of 0.5–0.6 m3 of expanded clay per 1.4–1.5 tons of sand-cement composition.
If the task is to prepare materials for wall structures, then the optimal proportions will look like this:
- 1 part cement.
- 1.5 parts of expanded clay sand with a fraction of up to 5 mm.
- 1 part of fine expanded clay.
If you want to create expanded clay concrete for floors, it is better to use such a batch: 1 part of cement, 3 parts of sand, 1.5 parts of water, 4-5 parts of expanded clay.
Types of placeholders
A variety of components can be used as fillers for expanded clay concrete. In addition to expanded clay or expanded clay sand, quartz sand or a larger additive, including gravel, can be used. In this case, expanded clay will play the role of the base.
Among the main varieties of fillers are:
- Gravel with an angular or rounded shape.
- Crushed stone with an irregular angular shape and a rough surface.
Depending on the bulk weight, 12 grades of expanded clay are distinguished, and two types (A and B) are used in terms of strength. Preparing claydite concrete blocks at home is much easier than it might seem at first. The main thing is to follow the above recommendations, to follow step by step instructions and do not deviate from the established recipe. In this case, the final raw material will be of the highest quality, reliable and durable.
