Rapid development advanced technologies led to the emergence of unique building materials, including expanded clay concrete. This type of concrete meets 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, which are characteristic 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/mC.
- Frost resistance - 50−200 cycles.
- Shrinkage - 0% mm/m.
- Moisture absorption - 50%.
When making expanded clay concrete with your own hands, the proportions are chosen 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 the series key characteristics expanded clay concrete.
Externally, expanded clay concrete is characterized by a cellular structure with different sizes pores (it is determined by the firing mode of the main filler). Depending on the porosity, three types of material can be distinguished: large-porous, porous, and dense.
As for the performance properties and advantages, they directly depend on the homogeneity of the structure concrete mixture. Standard strength indicators are determined by the correctly selected ratio of expanded clay gravel with fine and coarse fractions. If the material is to be used as a 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 thermal insulation layers in multilayer building forms. The characteristics and performance of the final composition depend on the selected proportions and compliance with the correct ratio of components. It is important to understand that the formulation of expanded clay concrete for floors and building blocks differs significantly.
When laying the screed, the type of surface should be taken into account, as it determines the composition of the mixture. The optimal proportion for making a screed with a height of 30 mm per 1 m² is as follows: 40 kg of a mixture of M300 sand concrete and 35 kg of expanded clay gravel.
Advantages and disadvantages of screeds
Expanded clay concrete screeds guarantee high reliability of the floor base, as well as its resistance to moisture, air and negative temperatures. Among the key advantages of the design, the following points should be highlighted:
But, in addition to the advantages, expanded clay 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 grind the floor surface after the composition has dried.
Production technology
The technology for producing expanded clay concrete blocks is particularly simple and accessible, which makes it especially popular among a wide audience of builders. Such material can be used for the construction of a small residential or utility structure in a dacha or area near a house, the construction of premises for insufficient good soil 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 much difficulty directly on a private plot, without using complex equipment and assistance from specialists.
Expanded clay concrete blocks can be either hollow or solid. Moreover, regardless of the shape, they include the main filler - expanded clay gravel. Solid structures are in demand for arranging the foundation and cladding external walls, while hollow structures act as a soundproofing and heat-insulating partition between the internal and external walls of the building.
When using porous technology, it is possible to increase the load-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 costs construction works, long service life of the product and low weight of expanded clay concrete.
Composition and proportions
Without a doubt, expanded clay 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 kinds of impurities and chemicals. It should be noted that in no case should you use water with an acidity below pH 4 to dilute the mixture. You should also not use 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 for construction site) may include several additional additives such as sawdust, wood ash and plasticizers.
To the future mortar met all the requirements, You must adhere to the following recommendations and rules:
- You can increase elastic properties using quartz sand.
- To make the future block moisture-resistant, you need to add expanded clay gravel (without sand) to its composition.
- Portland cement under the M400 brand is characterized by excellent astringent properties, so it is better to give preference to this particular model.
- The cement mixture has a positive effect on the strength properties 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 added to the expanded clay concrete blocks. Proportions for material with normal density imply the introduction of coarse-fractionated expanded clay. In most cases, such blocks are used to construct heat-insulating partitions.
If we are talking about the construction load-bearing walls new structures, it is advisable to use small 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 the mixture, you need to carefully study the recipe and pay attention to several recommendations. This will avoid many difficulties in different stages production, as well as get a high quality product with the best characteristics:
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 whether it spreads or not. If the slide begins to spread across the shovel, this indicates that the expanded clay concrete is too liquid. If the consistency is stable and not friable, then the required ratio of components has been achieved.
Depending on the design features, expanded clay blocks are used different brands concrete:
- 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 - used in the construction of premises with a small number of floors, insulation of enclosing structures and arrangement of monolithic floor slabs and screeds.
- M150−200 - this grade of concrete is used for the construction load-bearing structures and when creating wall blocks or panels. The material is distinguished by its ability to withstand strong temperature changes and chemical exposure.
- M200 is a popular composition for creating lightweight blocks and floors. The advantage of the material is its resistance to moisture and chemicals.
Mixtures of expanded clay blocks
As mentioned above, the proportions and recipe for 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, mix one part of cement and 2-3 parts of sand.
- After obtaining a homogeneous mass, add 0.9-1 part of water 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 wet enough, it is better to increase the volume of water. If good sand is not available, you can use “Sand Concrete”. When making expanded clay concrete for the floor, mix one part cement and one part water, three parts sand and two parts expanded clay. For wet CB screeds, it is customary to use expanded clay gravel in the proportion of 0.5−0.6 m\3 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 fine expanded clay.
If you want to create expanded clay concrete for floors, it is better to use the following mixture: 1 part cement, 3 parts sand, 1.5 parts water, 4-5 parts expanded clay.
Types of Aggregates
A variety of components can be used as expanded clay concrete fillers. In addition to expanded clay or expanded clay sand, you can use quartz sand or a larger additive, including gravel. In this case, expanded clay will act as a base.
Among the main types 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 in terms of strength, two types are used (A and B). Preparing expanded clay concrete blocks at home is much easier than it might seem at first. The main thing is to follow the above recommendations, follow step-by-step instructions and not deviate from the established recipe. In this case, the final raw material will be of the highest quality, reliable and durable.
Expanded clay, like bulk insulation, is used not only for thermal insulation measures related to the insulation of floors. It is often used for the production of concrete blocks, where it acts as a filler. This makes the blocks lighter, because expanded clay is several times lighter than gravel or crushed stone, which it replaces in expanded clay concrete blocks, plus the thermal conductivity of the concrete block itself is reduced. wall material. The production of expanded clay concrete blocks is no different from ordinary concrete blocks, the main thing is to strictly follow the recipe of the solution used.
Let us designate the composition of expanded clay concrete for the manufacture of blocks per 1 m³ of prepared mortar.
The above recipe corresponds to concrete grade M150, which is sufficient for assembling wall structures.
Today, much attention is paid to such characteristics as moisture resistance. Therefore, to produce expanded clay concrete blocks that could easily withstand high humidity and even direct exposure to water (for example, slanting rain), add to the solution waterproofing materials. One of them - bitumen mastic, mixed as a 10% aqueous solution.
It should be noted that this solution has a slightly modified recipe.
There are different approaches to the production of expanded clay concrete blocks. Production line with powerful equipment and high performance, where dispensers are installed, set to weight limits exactly according to the recipe. The second is the manual method, where weighing of components is often done with buckets. Therefore, it is worth indicating the weight of materials in buckets (10 l):
- cement – 13 kg;
- sand – 16;
- water – 10;
- expanded clay (gravel) – 4-4.5;
- expanded clay (sand) – 5.5-6.
Equipment for the production of
For the production of expanded clay concrete blocks ( manually) required:
- concrete mixer;
- several shovels;
- machine with vibrator;
- several forms.
A concrete mixer can be purchased or rented. Machine tools are also sold, although they are not the cheapest equipment. You can make them yourself, and if you are a good welder, then one machine will require one day of assembly. There are a huge number of machine designs. These are mainly frame units, with forms installed and rigidly fixed inside. A vibrator operating from a 220-volt network is also rigidly attached to the frame. The device is sold in construction stores.
Another option is a vibrating table, which is a horizontal plane. It is usually installed on springs, and a vibrator is attached to it. For the machine you will have to make several molds with your own hands. And what larger area table, the more molds can fit on it, the higher the productivity of homemade equipment.
Important! Do not overdo it, because the vibrator has a certain power, which is enough to vibrate a certain mass.
Mold for expanded clay concrete blocks
Various are used to make molds. flat materials: sheet iron thickness of at least 2 mm, boards, plywood, OSB boards, etc. The main task of the work manufacturer is to adjust the dimensions of the mold to the dimensions of the block: 190x188x390 mm (standard load-bearing wall block). There are so-called semi-blocks (used for the construction of partitions), dimensions: 90x188x390.
One of the features of expanded clay concrete blocks is the voids that lighten the stone without reducing bearing capacity, reduce costs by reducing the volume of mixture used, and increase the thermal properties of the product. Therefore, during manufacturing, three pipes with a diameter of 40-50 mm are rigidly installed in the molds, located at the same distance from each other and the walls of the mold.
The pipes are connected to each other by welding with horizontal bridges (reinforcement, angle or steel strip). They are attached to the walls of the mold by electric welding if the mold is made of steel sheet, or using self-tapping screws if wooden products are used.
Production technology
The technological process itself is carried out in any room with a well-functioning ventilation system. The dimensions of the room depend on the dimensions of the machines used. Expanded clay concrete blocks After manufacturing, they must undergo a drying process, which is carried out in an open area on the street. If there is a chance of falling out atmospheric precipitation, then it is better to erect a canopy over the site.
First of all, the solution is prepared: cement and part of the water are poured into a concrete mixer. The mixture is stirred for several minutes until a homogeneous composition is obtained. Then sand and expanded clay are added to it in portions. At the end the rest of the water is added. The final solution should be thick and plastic.
After that, it is dumped from the concrete mixer into a container prepared in advance (trough), and from there it is transferred with shovels into forms laid on a vibrating table or installed on a vibrating machine. Before this, the walls of the molds are coated with waste technical oil so that the blocks can easily come out after hardening. The floor of the vibrating table or platform is sprinkled with fine sand to prevent the concrete from sticking.
The molds are evenly filled with the solution, for example, a couple of shovels of the mixture thrown into them. Then the vibrator turns on, uniform distribution occurs concrete mortar throughout the entire volume of the mold and its compaction. After which the process is repeated. This procedure is repeated several times to fill out the forms completely. Sometimes, to give more precise dimensions, the laid and compacted mortar is additionally pressed on top with a metal lid; it will create an even and smooth surface on the surface of the block.
In this form, directly in the molds, expanded clay blocks should last at least a day. After which they are pulled out and laid on the street area so that there is a gap of 2-3 cm between them. Expanded clay concrete blocks should dry for 28 days, which will give them brand strength. The material must dry evenly on all sides, so each block is turned from side to side during drying. If you place them on wooden pallets to dry, there is no need to turn them over.
Production of expanded clay concrete blocks as a business
Starting to produce expanded clay blocks to make a profit is not a problem. The main thing is to calculate everything accurately. As practice shows, the main requirement is not for equipment, but for the size of the room and the outdoor area. The larger they are, the more blocks can be laid for drying, which lasts about a month. Therefore it is proposed different variants drying. One of these is shown in the photo below, where special racks with blocks stacked on floors are visible.
Everything else depends on the cost of raw materials, which varies depending on the season. In summer, cement prices are always higher because demand for it increases due to increased construction volumes. This especially applies to the private sector.
Therefore, it is optimal to produce expanded clay blocks in the autumn-spring period. If the room is heated, then production is not stopped in winter. Consumption of finished wall material in winter is small, sometimes it is reduced to zero, but in summer the entire stock of products produced will be sold out. Here it will be necessary to recalculate its cost at the new price of cement and other components. This is where the big profits lie.
Those who have been in this type of business for many years have been trying to foresee everything. Someone is trying to purchase materials at a low price in the winter, but there is a caveat - cement loses its properties over time and quality decreases. Someone, as described above, is trying to increase the production of blocks in winter. In any case, this is a profitable business while construction is at its peak and building materials are in demand. Expanded clay concrete blocks are at the peak of popularity today due to their low price, high thermal properties and ease of installation.
IN modern construction A wide variety of materials are used. Everything depends directly on the scale of construction and the specifics of the structure. In the event that we are talking about the construction of a large multi-storey building, then you can’t do without big monolithic slabs. A completely different situation if you plan to build a small country house. In this case, expanded clay concrete blocks are suitable. It should be noted in advance that this is not only cheap, but also reliable.
As for expanded clay concrete blocks directly, this material can be produced in artisanal conditions. This does not require a lot of experience or money. Moreover, this is exactly the path that small manufacturers take, producing large volumes of expanded clay blocks while spending very little money.
In terms of strength, the material meets all necessary standards, so there should be no concerns. However Special attention you need to pay attention to the process of producing blocks, since mistakes can easily be made, and after construction you can encounter really serious problems.
In this article we will take a detailed look at the manufacturing process of expanded clay concrete blocks. This event has many subtleties that not only beginners, but also all people who have not previously dealt with expanded clay blocks need to know about.
Features of the material
The main feature of expanded clay is its strength. This suggests that this material can be freely used in construction. Expanded clay concrete is an almost eternal material that can withstand high loads, but at the same time it is lightweight, which greatly simplifies construction.
As already mentioned, expanded clay concrete is often used for small buildings. Thus, the material is perfect for the construction country house or a small garage or shed. If we have a house project whose dimensions are quite large, we should contact specialists who will tell you exactly whether expanded clay concrete can be used in the presented conditions.
Expanded clay concrete is a good replacement for brick. In terms of strength, of course, brick shows itself a little better than expanded clay concrete, but the second material has much more advantages. First of all, it is necessary to note the simplicity of laying the material. A lot of work can be done in one approach, and the overall construction process will not be long. Again, the weight of expanded clay concrete makes it possible to move the material faster, as well as to carry out masonry without outside help. Most often, the weight of brick is 2.5 times more than expanded clay concrete.
Advantages and disadvantages of expanded clay concrete
The material produced on the basis of expanded clay has a lot of positive aspects. It also has disadvantages, but their advantages easily overshadow them.
The positive aspects are as follows:
- Frost resistance. The material behaves well even with sub-zero temperatures. This is a really important characteristic if we are talking about the use of expanded clay concrete on the territory of Eastern Europe. You can be sure that the material will easily withstand any frost.
- Low water absorption. It is reported that the water absorption of expanded clay is no more than 7%. This suggests that the material will not lose its initial properties even if we have high humidity. it's the same important aspect, on which the durability of the structure depends.
- Excellent thermal conductivity. Expanded clay concrete can be used without special restrictions in a wide variety of climatic conditions, and the temperature inside the room will always be acceptable. In addition, this material interacts well with various insulation materials.
- Durability. Expanded clay material remains in the same state for decades. Not all materials can boast of such achievements. The durability of the material is positively influenced by the fact that expanded clay concrete is a fireproof material, which, moreover, practically does not absorb moisture. Moreover, there is no need to maintain this product. Accordingly, this is an excellent material for the construction of a country house, which does not have to be visited regularly.
Expanded clay concrete also has significant disadvantages that you need to know about first:
- Material cost. If you purchase expanded clay concrete from manufacturers, it will cost significantly more than brick. But at the same time, you need to understand that in many respects expanded clay concrete is superior to brick. For example, if we made a choice in favor of the first material, then there may be no need for vapor barrier or thermal insulation.
- Handicraft production and material properties. It is worth noting the fact that today expanded clay concrete is produced by numerous companies. But at the same time, many handicraft industries are engaged in the same business. In the latter case, it is very difficult to obtain a material with truly excellent characteristics, since there is a need for a large number of additives. And the production technology itself may differ significantly. In the same material we will consider the most common technology for the production of expanded clay concrete blocks.
Composition of expanded clay concrete
Of course, first you need to study the composition of the material. As already mentioned, there are different kinds given product, so the composition may vary slightly:
- cement mixture;
- expanded clay;
- sand;
- water;
- additives.
As for additives, they can be very diverse. Moreover, each owner can experiment himself and choose the most optimal properties of the future material. To do this, you can visit a hardware store and consult with specialists.
For example, you can use saponified wood resin, which can significantly increase the frost resistance of the material. This is especially important in cool climates. Some additives can improve thermal insulation, as well as many other parameters. But don’t think that by using a huge number of additives we will get an almost perfect material. In this situation, very possible unpleasant consequences, so it's best not to overdo it.
The ratios of the material components should be as follows:
- 1 part cement mortar;
- 1 part expanded clay (it is advisable to use a fine fraction);
- 1.5 parts expanded clay sand.
As for cement, it is best to choose the M 400 brand. The volume of additives required to create high-quality blocks should be discussed with consultants, since the values may differ significantly.
Also during the production process we will need the following tools and devices:
- concrete mixer;
- block molds;
- vibration equipment.
Molds for the production of expanded clay concrete blocks
Now on sale you can find many options for molds for producing concrete-based products. In this case, these forms are also suitable for the production of expanded clay concrete. If for some reason this option is not suitable, then you can make the forms yourself. Regular boards can be used for this. The most important thing is to make sure that the walls of the mold are even and smooth.
However, those forms that are available in hardware stores are much better than homemade ones. First of all, they are truly durable and can be used for several years. In addition, in such forms you can find elements to create voids in the material. This significantly saves construction resources.
If you decide to use homemade wooden forms, then you should understand that this is rather a disposable form, which is unlikely to withstand more than several cycles of material production. Another problem is that the wood surface may have a texture that makes the expanded clay material not have the smoothest surface. In such a situation, you can take tin and sheathe the inner walls of the mold. In addition, you can process the mold with machine oil. It is worth keeping in mind that concrete adheres too well to wood, so it will be very difficult to remove the product from the mold. Thus, it is best to create some kind of cladding that will greatly simplify the overall process.
The production process of expanded clay concrete blocks
- At the very beginning, the concrete mixer is loaded with all the necessary components. This procedure should be performed in a certain sequence. First, water is poured into the concrete mixer. After this, expanded clay can be poured inside the installation. Next, you should wait until the expanded clay is completely wet in water, after which you need to add sand and cement. It should be emphasized that expanded clay absorbs a lot of water, so you may have to additionally add a certain amount of liquid to the concrete mixer that meets the requirements.
- Only after all the above procedures can additives be added to the concrete mixer. Next, all the ingredients used are thoroughly mixed. Ultimately, the mixture should not fall apart, but it should not be too liquid either.
- The next step is to use molds and vibration equipment. It should be noted that in this case you can use both a vibrating platform and a vibrating table. Of course, in artisanal conditions, exclusively the second option is used, since a vibrating platform is an option for large-scale production and large volumes of material. The vibrating table can be purchased online or from large construction companies. retail outlets. This installation itself is quite simple; it consists of a flat surface of the lid table, springs that rest on the racks (legs), as well as a vibration exciter. You can use the usual imbalance, but the main thing is that this element creates vibrations.
- The forms are filled with the mixture. It is best to compact using several forms at once; this will significantly speed up the process. It is worth keeping in mind that this procedure will take no more than a few minutes. After the first approach, the mixture will settle a little. Then you can add more mixture so that the shape is complete, and the future block itself is even and corresponds to the required dimensions. If during the process the mixture, on the contrary, comes out of the mold, you need to remove it, otherwise after hardening it will be very difficult to do this.
- After this event, the forms should remain calm for a while. Over time, the mixture will harden and gain strength. Immediately after the expanded clay concrete has become strong, the material can be removed from the mold. If you use a store-bought mold, it is very easy to disassemble. Homemade wooden mold, you may just have to break it apart to extract the material. However, in both cases you need to be careful, since it is quite easy to damage expanded clay concrete.
The material cannot be used immediately in construction. The thing is that concrete takes a long time to gain strength. Moreover, the dimensions of the blocks may change slightly over time.
Approximately within a month ready-made blocks are not used in construction work. They must rest in a place that meets a number of requirements. We are talking about a dry place where there are no sudden temperature changes. Also, precipitation should not be allowed to come into contact with expanded clay concrete. For such matters, you can build a small canopy, which will be located near the house. Often construction work is carried out in warm period, so there shouldn’t be any problems with temperature changes. Additionally, you can cover the blocks with fabric or other material.
It is best to immediately release the required volume of material so that it can be immediately stored in a specific location.
After a month, expanded clay concrete can be used in construction. Moreover, it should be borne in mind that this event can be freely carried out in cool climates, since the material, as already mentioned, has excellent frost resistance.
The domestic market for building materials is developing at a rapid pace. The emergence of new technologies seems to be a good prospect profitable business in this domain. In order to establish profitable production at home, you don’t have to invest a lot of money. For example, it is profitable to start manufacturing expanded clay concrete blocks, which are gaining popularity due to their large dimensions and affordable price. The technology is simple and understandable, equipment from China or used can be purchased inexpensively, and there will be no shortage of customers.
At first, it makes sense to start producing high-quality blocks for building walls. The most popular products are brands 300, 400, 500, which can be produced in the following sizes:
- 190×190×390 mm.
- 188×190×390 mm.
- 200×200×400 mm.
When the process is put into production, you can start making decorative blocks from expanded clay concrete or other varieties.
Home production technology
The manufacturing process of expanded clay concrete consists of several successive stages:
- preparation of raw material mixture;
- molding of elements;
- hardening;
- drying expanded clay concrete;
- transportation and storage.
1. Preparation of the mixture.
The key to obtaining first-class products is high-quality raw materials.
- Expanded clay - granules obtained by firing low-melting clay. The particles at the fracture resemble frozen foam. Due to the density of the baked shell, expanded clay has good strength. Granules with a diameter of 4-8 mm have irregular shapes with rounded edges. If smaller fractions (expanded clay sand) are used in production, then they are measured in 2 times less than granular material.
- Cement must be perfectly clean and fresh. It is preferable to choose brands M400 or M500.
- Additives - to give the surfaces of the blocks gloss, glue is added to the composition. ceramic tiles or stone. The introduction of plasticizers (approximately 5 g per 1 piece) helps to enhance water resistance and frost resistance. They prevent the formation of cracks and abrasion. To reduce the weight of products, wood resin is added.
Depends on what properties it will have at the output. Approximate ratio of main raw materials:
- 60% – expanded clay;
- 20-22% – construction sand;
- 10% – cement;
- 8-10% – water.
You need to place the raw materials in the concrete mixer in the following sequence: water, expanded clay, cement and sand. Mix for no more than 2 minutes, the result is durable, reliable expanded clay concrete with low weight and excellent heat-insulating qualities. To make the blocks stronger, there must be more cement in the mixture. In this case, the thermal conductivity of the material increases and the walls become colder.
To make one hollow block you will need 0.01 cubic meters of solution. The weight of the undried product is 11 kg, in dry form - 9.5 kg.
2. Formation.
The prepared mixture is filled into special containers.
3. Hardening.
At this stage of the technology, the use of a vibration machine is necessary. Special equipment provides shaking of the molds, due to which the solution is evenly distributed and compacted. At the end of vibration, excess mixture is removed with a steel plate.
The process lasts two days. The hardened elements are dried directly in the molds naturally or in special cells. If plasticizers are present in expanded clay concrete, the drying time is reduced to 6-8 hours. After this, the blocks are removed from the molds and kept for outdoors 7-10 days.
5. Warehousing.
Stack in a dry, well-ventilated area.
Block production equipment
You can equip a mini-plant for the production of expanded clay concrete at home with the equipment that is more suitable for the price - manual or automatic. When choosing machines, the following factors should be taken into account:
- start-up capital;
- types and sizes of blocks;
- estimated sales volumes;
- supplier conditions: delivery, installation, commissioning, after-sales service.
The main units that are necessary for the production of expanded clay concrete blocks are a concrete mixer and. If there is a shortage of funds, many processes can be carried out manually. This will not affect the quality, but will only extend the deadlines.
1. Concrete mixer - a large container mounted on a movable axis, used to mix individual components into a single mass. Models differ in displacement (capacity) and number of revolutions per minute.
2. Manual vibrating machine – small-sized equipment, best option. The vibrator is fixed in the machine body and creates oscillatory movements of small amplitude. Thanks to this, the building mixture is evenly distributed throughout the mold.
3. Vibrating table - a machine that combines a vibrator and a metal tray with sides into a single structure. Block molds are placed on the table for compacting the mixture. The vibrator is mounted from below, which ensures uniform distribution of vibrations over the entire surface. At the end of the process, the forms are transferred to the drying place without removing them from the pallet. In one cycle, 4-6 elements can be produced. The disadvantages of the equipment include large dimensions and lack of mobility. A lot of manual work is required.
4. Mobile mechanized machines - equipment on small wheels, equipped with a supporting body and an automatic lever for removing molds. Some models are equipped with compaction presses. The vibrator is located on the wall of the housing and acts on the molds through impulses.
5. Vibropress is complex professional equipment used in industrial production. The machine is equipped with a hydraulic drive, which accelerates the hardening process of expanded clay concrete. Special parts for the formation of voids are fixed on ramps that are pressed into the matrices. The blocks are formed and hardened on pallets. The main advantage is the absence manual labor at all stages.
For large-scale production, complex equipment is used, which consists of several systems:
- concrete mixer with dispenser – measures and mixes raw materials;
- conveyor – moves the expanded clay concrete mixture;
- Vibropress - block molding.
Price
It is difficult for a novice entrepreneur to immediately acquire high-tech models famous brands. Therefore, you can buy used equipment or low-power machines from China. The cheapest equipment producing 20 blocks per hour will cost 5,000 rubles.
The complete set of budget production costs approximately 170,000 - 200,000 rubles. This allows us to produce 450-500 blocks per work shift.
Minimum equipment cost:
- 70,000 rubles – concrete mixer;
- 50,000 rubles – vibrating machine;
- 50,000 rubles – a set of forms.
The price of equipment for the production of 100 blocks per hour starts from 260,000 rubles. Mobile machine lines producing 500 blocks per hour cost 3-3.2 million rubles. Most Popular trade marks: Riphean, Condor, HESS.
Expanded clay concrete blocks are lightweight construction material, which has high levels of strength, practicality and, most importantly, can be done with your own hands. Despite low mass, modules have increased density, low thermal conductivity, variety model range. The environmental friendliness of the material is another advantage of the modules, therefore, if the developer wants to take the construction of the building into his own hands from the very beginning of the process, it is worth setting up the production of expanded clay concrete blocks on his site. Moreover, the production of expanded clay concrete blocks will require small financial investments, and the cost of the module will be significantly lower than buying a finished product from the manufacturer.
Equipment for the production of modules
To make expanded clay concrete blocks with your own hands, you need to purchase, rent or make the appropriate equipment, as well as buy high-quality raw materials. And here you shouldn’t be cheap - the more High Quality the source material turns out to be, the more durable and practical the modules will be. To facilitate the process and set up a line for the production of expanded clay concrete blocks in the quantity required by the developer, the following equipment will be required:
- Vibrating table;
- Concrete mixer;
- Forming metal pallets.
If finances allow, it would be a good idea to purchase a vibro-compression installation; it will replace two devices: molds and a vibrating table. It is also necessary to choose a good room with a flat floor and determine a place for drying the modules.
Important! Vibrating tables vary in brand and capacity: some of them produce up to 120 modules per hour, and some up to 70 units of production. For private use, small-format machines with a power of up to 0.6 kW and a productivity of up to 20 blocks/hour are quite suitable. Price gradation within $ 30 - these are ideal devices in their compact size, used for the production of expanded clay concrete blocks with your own hands in private housing construction.
Manufacturing a machine for the production of expanded clay concrete blocks on your own is also possible
Manufacturing a machine for the production of expanded clay concrete blocks on your own is also possible. With a little dexterity and little skills, the device will turn out no worse than a factory one, but its price will be 10 times lower. We offer a version of the simplest equipment for the production of expanded clay concrete blocks of the “layer” type - this is a unit equipped with a molding box without a bottom, a vibrator located on the side wall and handles for dismantling the matrix.
Important! The standard dimensions of one block are 390 * 190 * 188 mm, the permissible percentage of voids is no more than 30%, and the slots can have either a round or an oblong shape - the only important thing is that the void former is made in the shape of a cone, to facilitate the removal of the molding box from finished block.
To make the matrix, you will need a sheet of metal 3-5 mm thick, from which you need to cut a blank with a margin of 5 cm for the process of compacting the mixture. The mold is made in the form of a through box without a bottom. The weld must remain on the outside, otherwise it will ruin the shape of the module.
To ensure stability of the machine, strips of thin profile pipes are welded to the sides of the device, and the structure is equipped with rubber upholstery around the perimeter. It’s a good idea to equip the entire system with an apron to prevent the solution from spilling. But the vibrator is made from the engine of an old 150 W washing machine (this can be done by shifting the centers). A metal strip with an edge hole is attached to the shaft - an eccentric, the parameters of which are best determined by trial. If you still have questions about how to make a machine for making modules, watch the video - the answers will be complete and detailed.
Preparation and process of production of expanded clay concrete modules with your own hands
To prepare the mixture and blocks, you will need a mold with smooth surface. It is allowed to make blanks from metal sheet, and from boards - in this case, the finished module will turn out textured. The process itself includes 4 stages:
- Mixing ingredients strictly according to the recipe. In particular, sand makes up 3 parts of the total volume of the mixture, water – 0.8-1 part, as well as cement, but expanded clay makes up 6 parts. It is important not only to follow the recipe technology for the production of expanded clay concrete blocks, but also to mix the components correctly: first, water, expanded clay, then cement and sand are placed in a concrete mixer. When using additional components, they are also loaded into the container of the concrete mixer.
- After the process, the molding stage begins. The use of a vibrating machine will speed up the process: the mixture is placed into the mold, where the plate is previously laid, the vibration engine is turned on, and excess composition is removed.
- Lift the plate with the finished form using the handles, you get a full-fledged module, which is sent for drying.
- Drying lasts at least 48 hours, while the workpieces must be protected from the sun and rain. After drying, the plates are removed from the modules.
This is the fastest process in which making expanded clay concrete blocks at home does not cause problems. However, if you need to make expanded clay concrete blocks with your own hands more durable and dense, it makes sense to add a steaming process, then the material will gain increased strength and the time for concrete to gain grade strength will be reduced to 28 days.
The composition of the mixture varies, but sand, water, cement and expanded clay are the main components. As a supplement, you can add saponified wood resins, which increase the frost-resistant qualities of the material, and technical liginosulfonate, which increases the cohesiveness of the mixture.
And now a little more about how to make expanded clay concrete blocks yourself:
- To prepare the solution, the proportions and ingredients are as follows:
- Portland cement M400 or Portland slag cement – 1 part;
- Expanded clay gravel – 8 parts;
- Pure quartz sand - 2 parts and 3 parts for a textured layer;
- Clean water - calculation 225 liters per 1m3 of mixture.
Advice! To give plasticity, it’s a good idea to add a spoonful of regular washing powder or dish soap.
- All ingredients are poured into a concrete mixer, and here you should first pour out the dry ingredients, and only then pour in water. If the proportions are met, the consistency of the mass will be similar to plasticine.
Advice! The resulting block will weigh approximately 16-17 kg. In this case, the shape of the workpiece is allowed as standard sizes, and arbitrary: 390*190*14, 190*190*140 and others.
- The molds are installed on a flat surface, the inside walls of the workpiece are generously lubricated with machine oil, and the base is sprinkled with sand.
- Fill the molds with the mixture, compact it on a vibrating table or use it for this purpose. wooden block. Compaction is carried out until cement laitance is formed. After this, the surface is leveled and the workpieces are sent for drying.
Important! The formwork is removed no earlier than in 24 hours! It is important to protect the workpieces from direct sunlight, since uneven drying leads to cracking of the surface of the modules.
As you can see, it is not difficult to buy, make equipment for the production of expanded clay concrete blocks at home and carry out all the processes. But modules manufactured in this way will be no worse than factory ones.
We calculate the cost
All work requires preliminary calculations, otherwise there is no point in starting the production of expanded clay concrete blocks at home with your own hands. To calculate the cost, you will have to accurately find out the price of the components and understand how much a unit will cost finished material. In particular, considering a standard module of 390*190*140 mm, the solution volume is 14 liters. We subtract the void formers, which, as a rule, are no more than 25-30%, the result is equal to 11 liters of mixture. Now calculating the components:
- One piece requires 0.005 cubic meters of sand, which fills 5 liters of the entire volume;
- Expanded clay is required approximately the same as sand;
- You will need 1.25 kg of cement.
All that remains is to find out the price of the ingredients, take into account water and other components and calculate the cost per unit of the module. According to the most approximate calculations, it will be up to $5. As you can see, the price is incredibly low. However, for a complete picture, it is not enough to calculate the costs of equipment, labor costs and time, which any developer must include in the calculations. But even in this complete scenario, the cost of the block modules from which great walls from expanded clay concrete blocks made by yourself is still lower than from the manufacturer. Therefore, if you are planning to build your house on a site, watch again the material manufacturing technology, videos from professionals and start planning the process of launching the production of expanded clay concrete blocks on your site - it is profitable, practical and affordable for every craftsman.
