How to make aerated concrete blocks with your own hands

Today, materials that can be made with your own hands are increasingly used for construction by purchasing only the necessary ingredients. All of them are characterized by excellent performance features, durability; In the end, their cost is not too high. One such material is aerated concrete. Laying the blocks is simple, and the material itself has numerous advantages, including good thermal insulation properties, which are important for building a house.

Aerated concrete blocks have good thermal insulation properties.

Aerated concrete is not new to the market; it was first used for construction at the beginning of the last century. Its active use in the construction of buildings began about 10 years ago. Although the technology for making aerated concrete itself was patented by Erickson, an architect from Sweden, back in 1924.

Previously, aerated concrete was produced only in factory conditions, since this required strict adherence to technology and selection of proportions for mixing. The production itself is not complicated, but the weight of one block, which is obtained after pouring, is not the smallest, so the work must be done by at least two people.

To produce aerated concrete you will need:

Portland cement;
quartz sand;
aluminum powder;
water;
lime.

The manufacturing process itself is based on the use of one of 2 methods:

autoclave;
non-autoclave.

The first method is used in factory conditions, since it requires special equipment. After pouring, the blocks are sintered under specially created conditions. You won’t be able to create them yourself, so it’s more practical to use the 2nd method. Concrete is poured into molds and dries naturally. The aerated concrete block is then removed and, if necessary, cut into pieces. Although it is better to immediately use molds that correspond to the required dimensions for filling.

Components for making the mixture

To do aerated concrete blocks with your own hands, you need to prepare the following ingredients:

For each cubic meter of finished aerated concrete (output) approximately 250-300 liters of water are required. This must be clean drinking water. It is best to take it from surface layers any clean sources.
Approximately 260-320 kg of cement is required per cubic meter of finished aerated concrete. For self-made grades M500D0, M400D0 are used.
Quarry sand, river sand, purified. Its quantity per cubic meter of the finished mixture is 250-350 kg. It is best to take small ones, the particle size of which is up to 2 mm. Under no circumstances should the contents of branches, debris or clay be allowed.
Special additives for aerated concrete. Quantity 1-3 kg for each cubic meter of finished mixture.
Gas-forming agent, i.e. aluminum powder. 0.5-0.7 kg for each finished cubic meter of concrete is enough. Powder is needed so that the reaction necessary for gas formation begins in the mixture. During mixing, gas begins to be released, bubbles and cells form inside the concrete, which give the composition the qualities it needs.
Lubricant for containers in the amount of 0.3-0.5 kg per cubic meter. Before you start pouring emulsions, carefully lubricate the molds. Use of used oils should not be used as they contain large amounts of soot.

It is not so difficult to make, but it is important to strictly follow all stages of production and select the ingredients for the future mixture in the correct proportions.

Equipment list:

Forms for pouring future aerated concrete blocks, which can have different sizes. It is best to purchase ready-made containers.
Strings that are necessary to remove excess mixture from the surface of the molds.
A concrete mixer that will be used to mix the mixture.

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Ingredient Requirements

It will not be possible to make a large volume of building material on your own, but for the construction small house they will be quite enough. Weight of one block standard size can be approximately 650 kg. Therefore, it is necessary to have several people present not only to lay the walls, but also to fill the forms and pull out the aerated concrete blocks from the containers. If all conditions are met, aerated concrete blocks will be durable and of high quality, and their cost will be less than when purchasing ready-made material.

Can be used special installations that mix aerated concrete automatically. They can be rented, but the equipment independently doses the ingredients and mixes concrete of the exact quality required. Rental costs will be justified.

The proportions of aerated concrete may vary, but it is best to adhere to the following formula (for aerated concrete D-600):

Portland cement PC500 D0 - 65%;
purified sand - 30%;
dolomite - 5%;
H/T - up to 0.48.

Lime flour, i.e. dolomite, can contain up to about 10% of aerated concrete, but it is important to decide what color of blocks is needed. With more lime, the color of aerated concrete blocks will be lighter. A large number of powder is also not required; it acts as a catalyst for the gas formation reaction.

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The process of making aerated concrete

To make cellular concrete, several steps must be followed, which include:

dosage of ingredients, mixing of the dry mixture;
adding water, mixing the solution;
filling the resulting mass of molds for filling;
holding the mixture to gain strength, drying the aerated concrete blocks and removing them from the molds.

It is necessary to carefully measure all the dry ingredients needed for the production of aerated concrete blocks. The main materials are cement, lime, sand. To start the process of gas formation, it is necessary to use aluminum powder. After reacting with water, it provokes the release of hydrogen, and the mixture begins to foam. Proportions are very important, since the strength, porosity and other characteristics of the future aerated concrete depend on them.

At the second stage, the components are mixed. The mass should be homogeneous. The quality of the mix determines what the aerated concrete will be like after preparation. For mixing it is necessary to use only special equipment. Concrete mixers are suitable; this process cannot be done manually.

When the future concrete is mixed, it is necessary to begin pouring it into forms.

Special forms are used; it is best to purchase ready-made ones that fully meet all the requirements.

Filling is carried out only up to half of the molds; under no circumstances should they be filled completely. This is explained by the fact that during gas formation the mixture greatly increases in volume, completely filling all forms. After the increase in volume is completed, using a metal rod it is necessary to remove all excess mixture from above so that the upper part is even and smooth. This is done approximately 6 hours after the filling has been completed.

As long as life has existed on the planet, so many people have been busy building their own homes. During this time, the technology of building houses, the building materials used and appearance erected buildings. Today, construction from aerated concrete blocks is relevant and you can build your own business on this. To start making blocks, you will need equipment for the production of aerated concrete, raw materials and space.

A budding businessman can purchase automated complexes for his own production, which will allow him to produce aerated concrete in small batches of excellent quality, practically no different from products manufactured on large production lines. However, the use of equipment for the production of building blocks will help save a significant amount and individual construction. The production of foam concrete is relevant when the construction site is located far from production workshops.

Selection of areas

At home, aerated concrete can be produced in open and closed areas. The main requirement for open space is the ease of movement of the loader and transport. Convenient high access for vehicles must be provided to the enclosed space. The room itself must be spacious to accommodate necessary equipment and provide space for pre-curing blocks. The building must be heated, with electrical and water supply.

When purchasing equipment, you should take into account the features of its operation:

Is it possible to produce aerated concrete of different densities?
What is the minimum product density?
Are there any guarantees for finished foam blocks?
Is there any provision of consulting assistance if necessary?
Power of purchased equipment. Up to 20 m 3 of products per day can be obtained at small construction sites. More powerful complexes produce up to 60 m 3 . Large-scale automated plants produce up to 150 m 3.

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It is possible to obtain high-quality products only by using good starting materials and following manufacturing technology. To set up the production of gas blocks that meet all the requirements of construction GOSTs, you will need:

Grade 400 Portland cement, which ensures the strength characteristics of the blocks.
Inert fillers.
Water purified from contaminants.
The gas-forming agent is aluminum powder.
Hardening accelerators.
Plasticizers.

The number of components used depends on the type of aerated concrete.

Technological process and its features

The connectivity and continuity of the entire process chain can be ensured by the correct placement of all components. For small production, there is no point in buying special containers designed to store the starting material. If it is planned to organize the production of blocks in large volumes, storage facilities are simply necessary.

Depending on the type of equipment you choose, you can automate individual stages of work or the entire process.

Dosage of raw materials and their supply to the aerated concrete mixer is possible both manually and automatic device. When mixing manually, the sound and heat insulation properties of the blocks may be impaired. Automatic equipment for aerated concrete makes it possible to produce blocks with the required characteristics.
Gas generator input.
Mix ingredients for 10 minutes.
Pouring the finished mixture into molds.
To complete gas formation, the mixture is left for 2 to 4 hours.
Excess material obtained during the process of increasing the volume of the solution is cut off to obtain an even shape.
The raw blocks are left in the molds for at least 8 hours to cure.
The finished aerated concrete blocks are removed from the molds and left to dry for 48 hours on wooden pallets.
To ensure full maturation, the blocks are transported to a warehouse for 28 days.

To produce autoclaved aerated concrete, you need more equipment complex design. Equipment from China for the production of blocks in an autoclave makes it possible to achieve a high efficiency rate and is used mainly in stationary factories high power. For small private enterprises, the purchase of such equipment is unprofitable.

Blocks made using heat treatment are distinguished by their quality, plasticity, high thermal insulation properties, and with a larger volume they have little weight, and are used for panel coverings, partitions and wall blocks.

The high cost of obtaining autoclaved aerated concrete is the main obstacle to its use in small businesses.

Fixed lines

For your own small business, stationary lines for the production of non-autoclaved aerated concrete are best suited. The maximum productivity of such lines reaches up to 60 m 3 of products. Stationary lines allow maximum automation of production, which significantly reduces the use of manual labor.

Special equipment is used to store and transport the starting components. Automatic dispensers quickly and accurately measure the amount of components required by technology. Cement is supplied to the dispenser by a screw feeder. A belt conveyor is used to supply sand sifted on a vibrating sieve. The water is heated in the boiler to 50 °C and then enters the dispenser.

The productivity of the entire line depends on the volume of the aerated concrete mixer. To properly accommodate all the necessary equipment and ensure uninterrupted production, an area of about 500 square meters is required. meters. With maximum automation, a fixed line can be operated by only 2 people.

The blocks are of excellent quality. The disadvantage of such lines is the need for a large area and capital investment for the purchase of equipment.

Mini lines

Stationary sets of equipment in a significantly reduced version, these are mini-lines. The technology for manufacturing blocks at such small complexes is no different from production at stationary devices. The quality of the products is excellent and the volume of finished blocks is significantly smaller. You can make up to 15 m 2 blocks per day.

The block molds are stationary, and the mixer moves on wheels. The speed of work is somewhat reduced due to the fact that the dosage of starting materials is done on floor scales. The production of aerated concrete blocks at home on mini-lines requires a working area of no more than 140 square meters. meters. Lower automation requires hiring more work force. It takes two people to produce a daily quota of products.

The unit can be transported from place to place while maintaining production volume. Convenient, comfortable equipment can be powered by a mobile power station or a mobile generator, which allows its installation directly on the construction site. The price level of the mini-line makes it possible to start developing a business with minimal investment.

Mobile installation "Aerated concrete-500 B plus"

Planning to build own house, purchase a mobile installation for the production of non-autoclaved aerated concrete and save a decent amount on the purchase of high-quality building materials.

When purchasing “Aerated Concrete-500 B Plus” equipment, the kit will include not only an installation for preparing the mixture, but also a compressor that ensures the quality of mixing, a special kit for connecting the installation and the compressor, recommendations and production technology, an electric motor, a pouring hose and a disk with full description all stages of work.

Using a compressor when mixing the composition makes it possible to improve the quality of mixing, and this:

Increased productivity by 30%.
Improved mix quality for aerated concrete.
Saving consumables.

In addition to the low price of the installation, attention is drawn to its reliability and ease of operation. To start preparing blocks, there is no need to obtain special qualifications. It is enough to carefully familiarize yourself with the manufacturing technology of aerated concrete blocks and take into account the recommendations of specialists.

Making aerated concrete on your own using a mobile installation does not require a special connection to three-phase network. The unit operates on a regular 220 V network. Another positive advantage of using a mobile unit is small area premises.

Conveyor line

When your production gains strength, you can think about purchasing a conveyor line and increase productivity finished products up to 150 m2. Increased productivity occurs due to maximum automation and minimal use of manual labor.

Business development involves expanding production space. To install a conveyor line you will need over 600 square meters. meters of area and up to 8 staff.

The conveyor line is different in that the molds move, but the dispenser and gas concrete mixer remain stationary. Well-established sales of finished products and large production volumes make it possible to recoup the high cost of equipment in a short period of time and make a good profit.

Cost of equipment

The price level for equipment for the production of aerated concrete blocks depends on the capacity and configuration. The most expensive thing is an aerated concrete mixer. The bulk of the price is made up of dispensers and forms.

You can buy a mini-line for 375 thousand rubles, or you can buy a conveyor line for 2,097,000 rubles. It all depends on financial capabilities and expected production capacity.

The need for aerated concrete building blocks is increasing every day, and this is an excellent prospect for beginning businessmen.

Articles

Today, the technology for the production of aerated concrete blocks is of interest to everyone who plans to build Vacation home or open a business for the production of cellular concrete. After all, this building material is a very good choice in terms of strength and thermal insulation characteristics, and besides, the production of aerated concrete can be quite a profitable business project.

What you need to know about cellular concrete?

Aerated concrete is fake diamond with microscopic air pores. Another name for it is autoclaved cellular concrete, and this in itself speaks about the technology of its production. Aerated blocks have excellent energy-saving characteristics precisely due to their porous structure. In addition, they are distinguished by their relatively low weight, including compared to brick and other types of building ceramics.

Aerated concrete blocks are a building material that can be used both for the construction internal partitions, and for load-bearing structures. It won't suit high-rise buildings or industrial facilities, but in individual construction it has proven itself to be excellent. Relatively lightweight gas blocks do not place a large load on the foundation, which reduces the cost of foundation construction. In addition, they have large sizes, and this allows you to speed up the construction process.

Composition of aerated concrete blocks

All of the listed advantages of this building material are due to its composition. All that aerated concrete consists of is cement, quartz sand and a gas-forming agent, which is aluminum powder. Some manufacturers add gypsum, lime, ash, and other ingredients to the composition.

Thus, aerated concrete is made on the basis of dry components that are mixed with water. Any technical equipment is suitable for these purposes. pure water, meeting the requirements of GOST 23732-79. The temperature of the water is important. It is desirable that it should not be lower than 45°C, since this will speed up the hardening of the blocks, increase their strength, and for the enterprise this is beneficial because it will increase the productivity of the line as a whole. Thus, many manufacturers heat the water because higher temperature means better quality material. It also helps reduce the amount of cement used, since heating the water stimulates the activity of the dry components of the mixture.

The production of aerated concrete requires a rather serious approach to the choice of sand. Theoretically, both quarry and river sand are suitable for these purposes, but it is important that it contains as few silt or clay particles as possible. It is also important to choose the grain size - no more than 2 mm. The technology for producing aerated concrete using the autoclave method makes it possible to replace sand with slag or ash obtained from metallurgical production. Thermal power plant ash helps produce aerated concrete with a lower density. This helps further reduce material production costs.

For the production of aerated concrete blocks, Portland cement grades M400 and M500 are required. It is best that Portland cement meets the requirements of GOST 10178-85. But the aluminum powder should be grade PAP-1 or PAP-2 - it acts as a gas generator. Sometimes a special paste is used for the same purpose. It can also be a suspension, since powdered aluminum is not so convenient when mixing the solution. Suspensions based on it can also be used.

What is the effect of aluminum powder based on? It reacts with cement or lime mortar, which has alkali properties, and during this chemical process, calcium salts (aluminates) and hydrogen gas are formed, which ensures the formation of pores.

For the production of aerated concrete, it is very important to make the correct calculation of the consumption for each component of the feedstock. There are standard recommendations for autoclaved gas blocks. Based on this recipe, the entire volume of the mixture is filled with 50-70% cement, 0.04-0.09% aluminum powder and up to 20-40% sand. In addition, you will need water (0.25-0.8%) and lime (1-5%). Thus, in order to get 1 cubic meter of aerated concrete, you need to take up to 90 kg of cement, up to 300 liters of water, lime - 35 kg, sand - 375 kg, aluminum powder - 0.5 kg. But this quantity can be adjusted under the conditions of a specific production, depending on the quality characteristics of the raw materials themselves.

What equipment will you need?

The technology for making aerated concrete is relatively simple. However, you won’t be able to get by with handicraft methods here. You need to purchase special equipment, which is usually ordered as a package from the manufacturer or its official representative - this is the most profitable option. This is not just one installation, this is a whole automated mini-factory. Sometimes the manufacturer even provides the services of a specialist who will advise on the installation of such a line, help set it up and select the optimal composition for the mixture used for such equipment.

Mini-plant for the production of non-autoclaved aerated concrete

The line includes various devices, and theoretically, each of them can be purchased separately if for some reason one fails. We are talking about such things as forms and mobile pallets intended for their transportation, devices for cutting finished blocks, mixers for aerated concrete, dispensers for bulk materials etc. But the main thing is an autoclave oven, because we are talking specifically about the production of autoclave gas blocks, which are distinguished by the highest quality characteristics.

Equipment for the production of aerated concrete is divided into several types. The choice of a specific option depends on the required daily productivity, how many workers the entrepreneur plans to hire, and how the shifts will be organized. The following options are possible:

Stationary lines have a daily productivity of up to 60 cubic meters of finished products. As a rule, they require warehouse and production facilities with an area of at least 500 m². The main feature of such lines is that the forms approach stationary installed mixer and there they are filled with solution, after which all the rest are completed technological stages. This is very simple technology, in order to service such a line, it is enough to hire one additional employee.
Conveyor lines are needed where needed high productivity- up to 75-150 m³ per day. Here production is carried out at a faster pace (of course, the ripening time of the product does not change, this does not depend on the line). However, conveyor lines require large areas production premises, and to service them you will need at least 8 people, although most technological processes Here it happens automatically.
Mini lines can't boast high performance, up to 15 cubic meters of finished blocks per day. The difference from stationary lines is that the mixer moves in them, and the forms are installed stationary. The main advantage is that they do not need large production areas, 140-160 m² is enough, so they are popular as a starting option.

In private construction, mobile installations are often used, which are needed for self-production of gas blocks. This pays off, and according to experts, construction costs are reduced by approximately 30%. Mobile units are supplied complete with a compressor. They even work from household electricity.

Production stages

There are two types of aerated concrete - autoclaved or non-autoclaved. The latter option is cheaper, although the resulting material has lower strength. However, due to the fact that its production cost is lower (no need to buy an autoclave, maintain it, pay extra for energy), it is a fairly popular option, so it is worth considering in more detail. If an entrepreneur intends to produce non-autoclaved aerated concrete, the production technology for it should be reduced to the following main stages:

Accurate dosage of all the components described above, and then mix them thoroughly. If you have the appropriate equipment, this stage takes no more than 10 minutes.
Using special equipment, the prepared mass is unloaded into special molds (they are filled only halfway, since the mixture will increase in volume during gas formation). This process will take place within 4 hours. During this time, the mixture fills the volume allotted to it in the form, and sometimes even this is not enough for it. Then after 2 hours the excess can be removed.
The curing process of the products takes about 16 hours, and after this period they are stripped and reloaded onto pallets, where they will gain so-called tempering strength. This stage takes another 2-3 days. After this, the products can be sent to the warehouse, but it is still too early to sell them, since they will gain their brand strength only on the 28th day.

The production of aerated concrete blocks using an autoclave in the first stages is practically no different from the technology described above. First you need to measure required amount all components (it is advisable that this be done using dispensers, this will help improve accuracy). Then this entire mass is loaded into the mixer and mixed thoroughly. Sometimes experts suggest using a concrete mixer for these purposes. Then a gasifier is introduced - this happens after 10-15 minutes of mixing the initial ingredients. Aluminum powder reacts with the solution in any case; it does not require autoclaving for this.

The semi-finished product is poured into molds, kept for the required 4-6 hours, after which the gas blocks are cut. They should sit for another 10-18 hours before they gain strength.

But the most important thing is to know how autoclaving is done after all the procedures described above. The formed blocks are reloaded into a special oven, into a sealed chamber, where high temperature Each block is treated with saturated water steam. The pressure should also be high - up to 12 kg/cm².

Non-autoclaved concrete is dried naturally, but this is not necessary for autoclaved products. Nevertheless, they also need to be kept for about 28-30 days in a warehouse, where they will gain brand strength.

It is not enough to know how to make aerated concrete; you also need to be able to deliver it to the consumer. To do this, gas blocks are packaged in a special shrink film and transported on wooden pallets.

Comments:

Reduce the cost of construction even more own home or a dacha, you can if you make aerated concrete with your own hands. have long become indispensable building material for quick and inexpensive construction of various buildings.

The composition of aerated concrete blocks includes: cement, lime, quartz sand, gypsum stone, aluminum powder and water.

There is nothing complicated in the technology for manufacturing non-autoclaved porous concrete. The composition includes accessible and widely available materials, and the maturation conditions for the composition are normal. All this suggests that it is possible to make aerated concrete with your own hands.

Features of aerated concrete

Aerated concrete blocks are regular parallelepipeds made of porous concrete. The material itself is a type of cement-based concrete in which air pores up to 3 mm in size are evenly distributed. Aluminum powder or paste is usually used as an additive to form pores. In general, the concrete mixture has the following composition: cement, sand, aluminum powder, water, and various additives.

According to the manufacturing method, aerated concrete is divided into autoclave and non-autoclave. The first type of material is obtained in an autoclave at elevated pressure and temperature, which is realized only in industrial conditions that ensure proper control of the process in extreme conditions.

The non-autoclave manufacturing method is implemented under natural conditions, which allows you to use it yourself. The production technology is based on the fact that when aluminum powder comes into contact with water, a violent reaction occurs with the release of carbon dioxide. If this process occurs in a closed form inside a viscous mass, then the gases form pores in the volume of this material. Even after the gases leave the mixture, the pores remain in the thickness of the mixture. After the mass hardens under normal atmospheric conditions, aerated concrete is obtained, i.e. concrete with closed pores in a shape close to round, with a diameter of 1-3 mm.

The porous structure provides the main advantages of the material, namely high thermal insulation properties combined with low specific gravity with sufficiently high compressive strength. Aerated concrete blocks have a density from 300 to 1200 kg/m³, depending on the amount of pore-forming substance introduced.

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Manufacturing Features

The technology for producing non-autoclaved aerated concrete includes several mandatory stages and conditions. The pore-forming component is added to the cement-sand mixture and distributed evenly throughout the volume. The process of pore formation occurs quite actively with the expansion of volume when the powder comes into contact with water.

To retain the pores inside the mass, the gas evolution reaction must occur in forms that have sufficient strength. The internal cavity of the mold determines the dimensions of the resulting aerated concrete block. For the initial hardening of the mass, at least 2 hours are required. After this, the concrete can be removed from the mold, but must remain stationary on racks until completely cured. The final strength value is achieved only after 28 days of drying the blocks. To make aerated concrete with your own hands, it is necessary to ensure that the basic conditions are met and to carry out a number of necessary works.

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Required Tools

To make aerated concrete blocks with your own hands, you will need the following tools:

Bulgarian;
hacksaw;
plane;
electric drill;
hacksaw for metal;
hammer;
shovel;
mixer;
ruler;
construction hair dryer;
Master OK;
putty knife;
steel string;
chisel;
chisel;
scales;
measuring bucket.

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Preparing the mixture

The standard mixture for aerated concrete contains cement, sand, water and lime. Aluminum powder is used as a pore-forming substance. Slaked lime acts as a plasticizer. To improve the properties, it is recommended to use additional additives: sodium sulfate (no more than 0.5%) and caustic soda (no more than 1.5% by weight).

The basis of aerated concrete is cement. It is recommended to use Portland cement grade M400 or M500. The filler is taken in the form of quartz sand. It should be thoroughly sifted to remove large fractions. Clay in sand can only be in the form of small traces and amount to no more than 7% of the weight of the sand. The following composition and ratio of ingredients are recommended concrete mixture:

cement - 50-70%;
sand - 20-40%;
lime, caustic soda, sodium sulfate - 1-5%;
aluminum powder - 0.04-0.09%;
water - 0.25-0.8%.

The mixture must be thoroughly mixed. By changing the cement content and pore-forming composition, it is possible to regulate the volume of pores in concrete, that is, change the density of the material.

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Mold making

In order to solve the question of how to make aerated concrete, it is necessary to ensure the production of a mold for pouring the concrete mixture. Such forms can be of two types. The first type (the simplest) is a rectangular box with a height equal to the height of the block. The area of the box must contain the volume of mass from which several (4-9 pieces) aerated concrete elements can be made. If a significant volume of production of gas blocks is planned, then it is better to make the mold from a steel strip 4-5 mm thick. The structure must be collapsible to facilitate the removal of the concrete blank. A removable cover must be provided on top. It is advisable to provide for its fastening to the sides of the box using bolts (screws) or other clamps. A simplified version of the form can be made from wood. For the sides of the box you should use a board 30-40 mm thick.

The second type of shape is a lattice system. In this design, the cavity of the box is divided by partitions into cells, in which one gas block is formed. This form can also be made of steel strip or wood. For internal partitions, plywood with a thickness of 12-15 mm can be used.

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Making aerated concrete at home

Before starting work inner surface The molds must be thoroughly lubricated with machine oil to prevent the mass from sticking. It is recommended to heat the mold to a temperature of about 40º C. Mix evenly concrete mortar aluminum powder is introduced and it is poured into the mold.

It is necessary to pour to a height approximately equal to half the height of the side of the box, which takes into account the expansion of the mass during passage chemical reaction with the formation of pores.

A violent reaction with the release of gas occurs within 6-8 minutes. At this time it is observed active growth level of mass in the form. At the end of the reaction, the expansion of the composition stops, and then a slight shrinkage of the solution occurs. After stopping the vertical movement of the level, using a strong steel string, all irregularities (bumps, sagging) are cut off from the surface of the workpiece. A heat-insulating material is placed on top of the calmed block blank: asbestos, foam plastic, etc. The mold is closed on top with a lid.

Natural drying of aerated concrete blocks is carried out. Minimum drying time is 2 hours. After this, the monolith can be cut into blocks the right size. The recommended time before transportation to the storage site is 24 hours. During the work, it is necessary to prevent the occurrence of drafts. Fan operation is not recommended. Cooling of the mass should be slow and uniform.

Private houses are often built from aerated concrete because this material, at a low cost, has excellent performance. Aerated concrete has been used in construction for a very long time. It has proven itself only on the positive side if low buildings (up to four floors) are being erected.

The production of this material is a complex and responsible process. Only if all conditions are met, high-quality products will be obtained that can be safely used in.

Main manufacturing stages:

Preparation of forms. Most often, a rectangular design is used, consisting of four sides and two. All structural parts are connected with bolts that can be treated with any machine oil.
Preparing the mixture. The initial components of the mixture are cement, lime, sand and warm water. A gasifier is also used. Sand must be screened out maximum size at 2.1 units. The clay content in sand should not be more than seven percent. As for cement, grades M-400 or M-500 are used. The ratio of components is approximately as follows: 51-71% cement, 0.04-0.09% aluminum paste, 1-5% lime, 20-40% sand and 0.25-0.8% water.
Filling the form. The mixture is poured into prepared molds, which must first be heated to 40 degrees Celsius. After the mixture is poured, its level is leveled with a stretched string. Then she covers herself thermal insulation material. This will reduce heat loss, which is necessary for the stable process of pore formation and hardening of the product.
Drying blocks. It is carried out within two hours after pouring. The block is pulled out of the mold and sent to a warm warehouse or special chambers to complete the production process.

Aerated concrete wall blocks are products made from cellular concrete. What are its features and what is this building material in general?

Aerated concrete was invented a long time ago, but with the development of new modern production technologies, improved aerated concrete blocks began to be produced various designs and types. When constructing buildings, several types of different blocks are used. about aerated concrete blocks for external walls.

Equipment for the production of

Depending on the volumes in which aerated concrete blocks are produced, the equipment will be different. Most often it is about fixed lines. They are suitable for the production of non-autoclaved aerated concrete.

Autoclaved aerated concrete gains strength at high blood pressure and temperature in special camera, which is called an autoclave. The non-autoclave option hardens in a natural environment using heat.

The maximum productivity of a fixed line is 60 cubic meters. This is an automated production that requires minimal human presence.

Special equipment helps with storage and transportation, and automatic dispensers themselves measure the required amount of components. The blocks are of high quality, but this is expensive equipment, which also requires a large area.

There are also mini lines, which are a smaller copy of stationary equipment. Here the work process is similar to the process described above, and the blocks are obtained good quality. The only difference is the smaller number of finished products.

The video shows the process industrial production aerated concrete:

Molds for production

The formwork method influences what forms of cellular aerated concrete production exist:

Collapsible. The mass poured into such forms can be combined by simply removing the sides. They are collected on empty pallets. Most of Work with forms is done manually, but this increases labor costs.
Caps. Such forms can only be removed from already frozen blocks. Removal is carried out using mechanical devices. Their frame is cast and cannot be disassembled. Such forms speed up the production process, but also require minimal manual labor.

After removing finished blocks from any type of container, it must be cleaned and thoroughly lubricated before launching a new batch.

You can make aerated concrete at home using special equipment. For example, the mobile installation “Aerated concrete-500 B plus” will help. The purchase of such a machine will ultimately pay for itself, because it will be possible to produce the required number of blocks for further use in the construction of a private house without the extra financial costs of searching for a manufacturer and delivering finished products.

The installation also includes:

Electrical engine;
Filling hose;
Disc with a complete description of all stages of work. Therefore, to start manufacturing, it is not necessary to have special qualifications. It is enough to familiarize yourself with the information on the disk.

And this is how they make aerated concrete with their own hands:

Cost of equipment

The final price depends on the power of the equipment and its specific configuration. Everything is expensive: a mixer, the main part of the price of which consists of the dispensers and the mold. A mini line will cost around 400,000 rubles. If we talk about the conveyor line, then the total minimum price will be around two million.

Despite the fact that aerated concrete blocks are a proven building material that has been used for a long time, it does not lose its relevance. The production is characterized by significant simplicity of the process, and the use natural materials for the mixture gives ready-made blocks many advantages.