Production of a foam block at home: technologies for the production of foam concrete. Necessary materials and tools. Production of foam concrete: from industrial to handmade
- Barotechnology
- Injection technology
- cutting technology
- Block drying
- Paperwork
- Tax regime
- Similar business ideas:
Foam blocks are a lightweight building material obtained by hardening a solution consisting of sand, cement, water, foam and chemical additives. The popularity of foam blocks is due to a number of advantages of this building material:
- Reliability. It is almost eternal, resistant to negative effects environment construction material;
- Heat. Foam blocks have high thermal resistance;
- Ease. Foam blocks are 2.5 times lighter than bricks and their consumption when laying walls is several times less than the consumption of bricks due to a decrease in the thickness of the walls;
- Soundproofing. A building built on foam blocks has a high ability to absorb sound;
- Fast installation. Laying foam blocks because of them big size and precise geometry passes quite easily and quickly.
- and many other benefits.
In this regard, there is always a demand for foam blocks from construction organizations and individuals.
The advantages of producing foam blocks are as follows:
- Low start up costs. About 300 thousand rubles are enough to organize a mini-production of foam blocks;
- Simple technology for the production of foam blocks;
- Stable demand for this building material;
- It is not required for the organization of production large areas and a large staff of workers;
- High indicators of economic efficiency of production. The profitability of the production of foam blocks is about 50%.
The production stages of foam blocks are as follows:
At the same time, depending on the type of equipment used and the production technology, the quality, cost, speed of production of foam blocks, etc. change. About everything in order.
Preparation of foam concrete mix
To date, two technologies are used to prepare the foam concrete mixture: barotechnology and the use of a steam generator.
Barotechnology
Barotechnology is more cheap way foam concrete production. This method of production does not require the purchase of expensive equipment and therefore it is very common in many small industries. The essence of barotechnology is that the main components of foam concrete are fed into the mixer: cement, water, sand, foaming agent, hardening accelerators, air-entraining additives (sometimes). Further, air is supplied to the mixer and all components are actively mixed. Then the resulting solution under pressure enters the injection molds, where the foam concrete mixture increases in volume and acquires its final shape.
The advantages of this technology:
- Low unit production cost and, as a result, low (competitive) selling price of the unit. The barotechnology production process is simple and does not require large capital investments. small production can be opened almost in "home" conditions.
Cons of this technology:
- Low strength of foam blocks due to a large number water used when mixing the foam concrete mixture;
- The large pore size of foam blocks, which also reduces their strength and ultimately affects bearing capacity building walls;
- Synthetic foaming agents and plasticizers used in the process of mixing the foam concrete mixture (to create the mobility of the mixture) negatively affect the environmental friendliness of the finished foam concrete blocks.
Production of foam concrete using a foam generator
The production of foam concrete using a foam generator allows you to mix the components of the foam concrete mixture in the correct dosage, which has a positive effect on the strength and quality of finished products.
The essence of this technology is as follows: with the help of dispensers, dry components in the form of cement and sand are first fed into the mixer, and then liquid components in the form of water with chemical additives. The mixture then begins to stir. Further, the finished technical foam is fed into the mixer and mixed with the cement-sand mortar. To create the required density of foam blocks, the required amount of foam is supplied by adjusting the operating time of the foam generator. Then the foam concrete mixture under compressor pressure is fed to the place of laying or into the molds.
Thanks to the precise regulation of the dosing and saturation process, the production of foam blocks reaches a completely different quality level.
The advantages of this technology:
- Higher quality of finished foam blocks. Thanks to the use of pre-prepared foam, stronger foam blocks are obtained at the output, without large air pores and with the correct structure;
- Environmental friendliness of foam blocks, as environmentally friendly protein foaming agents are used in the production process.
Cons of this technology:
- The high cost of equipment for organizing production;
- Higher cost per unit of production and, accordingly, high selling price of foam blocks.
To date, the molding of foam blocks is carried out using two technologies: injection and cutting technology.
Injection technology
Casting technology involves pouring the concrete mixture into special metal cassette molds. The most common cassette molds are 600mm high.
The advantages of this technology:
- Low cost of equipment (cassette molds);
- Ease of molding process.
Cons of this technology:
- The discrepancy in the geometry of the finished blocks in height, length and width. This is because when forming foam blocks, low-quality forms are used, often made in garage conditions. Qualitative forms are quite expensive;
- For the production of blocks of different sizes, it is required and different forms, which increases the cost of acquiring or manufacturing different forms;
- When stripping, partial damage to the corners and surface of the foam block occurs. This happens due to the block sticking to the walls of the cassette, and when it is removed, it has not yet gained the required strength. The foam blocks in the molds need to be allowed to stand for some time (about 10 hours), and due to the rush in production, this rule is often violated.
cutting technology
The cutting technology consists of two stages of block molding:
BUT. Casting the foam concrete mixture into a large mold and demoulding;
B. Cutting a large block into foam blocks of a given size.
This technology uses special cutting machines with different cutting elements (strings, band saws and chain saws).
The advantages of this technology are obvious:
- Excellent geometry of finished blocks, in accordance with GOST;
- There are no chips and damage to the surface of the foam blocks;
- Ability to produce blocks different sizes. This is achieved by reconfiguring the pitch of the saw strings.
Cons of this technology:
- When using different cutting elements, the requirements for the timeliness of the cutting must be observed. It is important to cut when the block has already hardened, but has not gained excess strength, otherwise the string may move, which will adversely affect the evenness of the block.
Block drying
Depending on the technology of forming foam blocks, the technology of drying products also differs.
With the injection method of production, drying of blocks can be carried out in two ways:
- Exposure of products in molds for 10 hours to gain strength and further stripping of foam blocks;
- Heat treatment of products in a steaming chamber, which allows the blocks to gain the necessary strength in just a few hours.
With cutting technology, a large mass of block is naturally cured for 4-12 hours and then further cut. The time for cutting into blocks of the desired size depends on the type of cutting elements and hardening accelerators added to the foam concrete mix.
How to choose equipment for the production of foam blocks
We list the main equipment used in the production of foam blocks:
1. Bar installation for the preparation of foam concrete mix:
The cost of such an installation is about 100 thousand rubles.
2. Forms used in the injection technology for the production of foam blocks:
A collapsible cassette mold for the production of blocks measuring 600 × 300 × 200 mm will cost about 30 thousand rubles. Up to 30 blocks are poured into this form at the same time.
3. Foam generator for the preparation of technical foam:
The cost of a new foam generator is about 90 thousand rubles.
4. Complex for cutting foam blocks:
The cutting complex is the most expensive equipment in the system for the production of foam blocks using cutting technology. On average, the price of one set is about 500 thousand rubles.
Other equipment used in the production of foam blocks include: mixing stations, compressors, vibrating screens, etc.
How much money do you need to start a business for the production of foam blocks:
- Creation of a mini-production of foam blocks using injection technology with the use of a pressure unit to create a foam concrete mixture. About 300 thousand rubles are enough to start such a business (if a room is found);
- Mini-production of foam blocks using cutting technology using a foam generator to create a foam concrete mixture. Starting costs - about 700 thousand rubles;
- Acquisition of a line for the production of foam blocks, including the entire range of expensive equipment: mixing stations, foam generators, cutting complexes, etc. The purpose of purchasing such a line is to create an enterprise for the production of a large volume of foam blocks. Start-up costs in this case will amount to several million rubles.
Brief business plan for the production of foam blocks
Calculate economic efficiency organization of mini-production of foam blocks, with a production volume of 330 m3 of foam blocks per month (22 working days) or 15 m3 per shift.
Initial data:
- Productivity per shift - 15 m3;
- Number of working days (shifts) per month - 22;
- Production area - 500m2, rental price - 50 thousand rubles per month.
How much money is needed to open a mini-production of foam blocks
The total initial investment for the opening of a mini production of foam blocks will amount to 421 thousand rubles.
The cost of materials for the production of 1 m3 of foam concrete
The total cost of materials for the production of 1 m3 of foam block is 1590.13 rubles.
Conclusion: Net profit based on the results of the monthly work of the enterprise for the production of foam blocks will be 406.4 thousand rubles. The profitability of production with such indicators is 60%, and the payback period of the equipment is only 1 month. Such indicators are possible subject to 100% sales of all manufactured products, which is 330 m3 of foam blocks per month.
Organization of a business for the production of foam blocks
The procedure for preparing documents for opening and developing your own company for the production of foam blocks includes the following steps:
- Collection of information and analysis of the situation on the building materials market.
- Creation of a business plan.
- Analysis of the financial situation (if your own savings are not enough, you need to look for alternative sources funding).
- Business registration.
- Search for premises for the workshop and administration.
- The conclusion of labor contracts with the personnel of the enterprise.
- Product certification.
- Purchase of equipment and tools.
- Signing contracts with suppliers, buyers, etc.
Solution of the above 
questions is a rather laborious task, therefore
many start-up entrepreneurs turn to law firms in order to receive a ready-made package of documents for a certain fee (the cost of services depends on the region of residence and other factors).
Paperwork
Preparation of papers for the legal production of foam blocks begins with the choice of legal form for your business. Registration of an LLC is carried out if the owner of the company plans to work with government agencies and large companies. Entrepreneurs who focus on working with individuals can register as individual entrepreneurs. In addition, you will need the following documents:
- permission from the fire inspectorate and Rospotrebnadzor;
- certificates;
- invoices for raw materials;
- contracts with contractors;
- bank account opening certificate.
Preparation of documents for the operation of an enterprise that specializes in the production of foam blocks is almost completely limited to the listed issues. For this direction commercial activities no permits or licenses are required. To register a business and the subsequent execution of reporting, banking and other documents, you need to indicate the activity code (according to the all-Russian classifier). In this case, this is OKVED 26.61.
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- for men
Despite the fact that I don’t like the phrase “production” and “home conditions”, but since people are interested in this topic, we will try to figure out how to organize a mini-production of foam blocks on our site.
I will say right away that business, and even more so production, on your site where you live is a violation of the law (not a criminal article, just a fine). Any industrial production(and the production of building materials is just that) cannot be organized where people live. To do this, there are special industrial zones or your company must be located at a distance of 300 meters from the nearest residential buildings. Therefore, if you start such a business at your side, then work quietly, but expect that sooner or later your office may be opened and you will have to communicate with regulatory authorities, pay more than one fine, and close the enterprise.
It is best to open a mini-enterprise in a rented room of 100 - 200 sq.m., which for a reasonable rent there are plenty in every city.
If the demand for the foam block?
Demand, of course, is, but supply is also high. The foam block is in demand due to its following qualities:
- low cost (houses in villages are now probably only built from it);
- the speed of building walls - building with foam blocks is much faster than with bricks (one foam block \u003d 4 bricks);
- high strength (but it is still not recommended to build buildings above 3 floors);
- excellent sound insulation;
- frost resistance and so on.
Nevertheless, when opening production, you will have to try to find someone to sell the foam block to. And you should look for buyers in advance of buying the equipment for the production of foam blocks. Otherwise, you will stamp a whole warehouse of goods, you will not be able to sell, but wages and other expenses must be paid. You can search for buyers by the following options:
- construction markets;
- construction organizations;
- chain stores selling building materials;
- wholesale buyers and individuals who can be searched through advertisements in newspapers, on websites, and so on;
- you can hang a banner on the track: “Foam blocks are sold from the manufacturer for low prices..., indicate the phone number.
When opening a business, it is important to take into account seasonality. The foam block starts to buy when it wakes up construction market. And it happens in the spring. It is by this period that production should be launched. In this case, the buyer can be expected already with the first foam block made.
I agree with the user under the nickname "granitos" from the biznet.ru forum, who says that it is best to produce foam blocks and engage in private construction. It turns out that you do not need to look for the sale of products: you sell the foam block to the end consumer. Here you have a profitability of more than 100%:
Case registration
Even being at home, you still have to register the case. It will be impossible to sell your products without the status of an entrepreneur: no one will work with the usual individual. Starting a sole proprietorship is not difficult.
IP registration in tax service takes only 5 working days from the date of submission of documents for registration. The procedure costs 800 rubles state. fees, and the list of documents is limited to a photocopy of the passport, TIN and application for registration. In the application for registration, you can specify the OKVED code 26.61 "Production of concrete products for use in construction."
As a taxation system, it is advisable to use the simplified tax system (simplified), 6% of revenue or 15% of profit. This special regime will save you from the obligation to pay income tax, VAT and property tax. You need to switch to the simplified tax system within 5 days from the date of registration of the IP upon application (it is better to do this immediately after receiving the certificate for the IP).
Equipment - we buy a line for production
There are plenty of offers on the market for equipment for the production of foam blocks. You can find configurations for 200 thousand rubles, and you can also for 1.5 million. The complete set of the line will depend on the desired production volume. In principle, high productivity is not needed for "home" production. For example, here is such a set of equipment for 270 thousand rubles, which includes a bar installation, a compressor, a foaming agent and molds for blocks (30 pieces).
Such a set will make it possible to produce up to 5 cubic meters for an 8-hour work shift by the efforts of two or three workers. foam concrete. In monetary terms, this corresponds to 10-11 thousand rubles a day. More than 100 cubic meters can be produced in 22 working days. foam blocks in the amount of 230 thousand rubles (revenue).
Briefly about raw materials and technology
The raw materials for the production of foam blocks are PC500D0 cement, water, sand, a foaming agent, mold lubricant. The approximate cost of raw materials for the production of 1 cubic meter. is 1600 rubles.
The production technology includes such stages as the formation of a foam concrete mixture in a pressure unit - unloading the finished foam block - demoulding (deforming) of the foam blocks - shipment of finished foam blocks on pallets - storage - formation of the foam block tempering strength within 2 days. Foam blocks acquire their final, 100% strength 28 days after production.
The average cost of production of 1 cubic meters. m. foam block is 2000 rubles, and the selling price is about 3000 rubles. That is, from 1 cu. m. foam block, we make a profit of 1000 rubles. We sell 100 cubic meters. per month and get a profit of 100 thousand rubles.
Business plan for mini production of foam blocks
Investments:
- purchase of a line (equipment) + delivery - 300 thousand rubles;
- preparation of the production site - 50 thousand rubles;
- purchase of raw materials and materials - 50 thousand rubles;
- other expenses (purchase of household equipment, overalls, and so on) - 100 thousand rubles.
Total: 500 thousand rubles
The cost of manufacturing 1 cu. m. foam blocks:
- cement PC500D0 (0.3 tons) - 1300 rubles;
- water (0.3 t) - 8 rubles;
- sand (0.2 t) - 50 rubles;
- foaming agent (1.16 tons) - 90 rubles;
- grease for molds (0.25 kg) - 10 rubles;
- electricity - 100 rubles;
- equipment depreciation - 300 rubles;
- salary - 400 rubles.
Total: 2258 rubles.
Profit per month:
- selling price of 1 cubic meter - 3000 rubles;
- profit from the sale of 1 cubic meters. (before taxation) - 742 rubles;
- production volume per month - 110 cubic meters;
- total profit (before taxation) - 81,620 rubles;
- tax (STS, 15% of profit) - 12,243 rubles.
Net profit per month - 69,377 rubles.
Payback business on foam blocks with 100% sales of products is 7 months. The real payback can be higher by 5-6 months, taking into account the seasonality factor and possible failures in the sale of products.
Foam concrete production
The method of preparation of molding foam concrete masses depends on the adopted technology and the type of foam concentrate used. Foam concrete production, regardless of the foaming method, is based on obtaining a heterogeneous gas-liquid-solid system (creation of cells or bubbles in a cement-sand mixture) and can be organized in several ways.
When choosing a method for the production of foam concrete, one should proceed from what characteristics are set for the material, from the ability of the enterprise to purchase the necessary equipment, as well as from the type of raw materials and a number of other initial conditions for organizing production.
In the technology for the manufacture of foam concrete mixtures, additional operations can be used aimed at optimizing the granulometric composition of the components of the raw mixture, regulating the porous structure of the mixture, the simultaneous use of foam and gas formers, the complex use of surfactants with a plasticizing effect and functional additives, for example, accelerating the formation of structure during hardening of the binder or stabilizing the structure of the foam concrete mixture.
Ingredients for the manufacture of foam concrete
The basis for foam concrete is cement. Manufacturers of foam blocks use Russian and foreign brands of cement. Domestic Portland cement grades 500 - 600-D0 and 500-D20 are best suited for foam concrete; 42.5R and 52.5R can be used from imported options. To save cement, you can add fly ash to the mixture. When using it, it is possible to reduce the amount of cement used up to 30% without significant loss in the quality of the final product.
The sand used in the creation of foam concrete can be quartz, river or washed. The maximum particle size modulus should not exceed one for washed sand, for river sand it should not exceed 0.7, for quartz - 0.3.
It is desirable to heat the water used to create the solution so that the foam concrete sets faster. It is also preferable to use soft water. To soften water, some manufacturers add to the solution liquid glass, but this is contrary to environmental standards.
In the production of barotechnology, synthetic foam concentrates are most often used. In classical technology, on the contrary, mainly natural components are used. Organic foam significantly increases the strength of foam concrete blocks. Synthetic foaming agents do not give such an effect.
Additionally, polypropylene fiber is added to the composition of foam concrete. You can add basalt or polyamide, but polypropylene is much more economical. You can add alkali-resistant glass fiber, but it is an order of magnitude less effective.
For the fastest setting of the foam concrete mass and for quick stripping, the addition of calcium chloride is allowed, which increases the heat release by 20%.
Foam concrete production technologies
The production of foam concrete mixture is carried out using technologies: classical, barotechnology, porous and dry mineralization.
Production of foam concrete using a foam generator (classic)
In classical technology, pre-prepared technological foam is mixed at low speed with cement paste or cement-sand mortar and a cellular concrete mixture is obtained. The concentrate of the foaming agent and part of the water are dosed by volume, then they are mixed to obtain a working solution of the foaming agent. The working solution of the foaming agent enters the foam generator to produce foam. The second part of the water is dosed by volume, cement and sand - by weight, and a mortar mixture is made from them. Foam from the foam generator and the mortar mixture are fed into the foam concrete mixer. The foam concrete mixture prepared in the foam concrete mixer is transported by pump to the place of laying in molds or monolithic structure.
Stages of production of foam concrete using a foam generator:
1) Preparation of raw materials. For the production of foam concrete, a foaming agent, Portland cement, unground fine sand, water with a temperature of up to + 25 ° C are used. Depending on the recipe and brand of the future foam concrete, special ready-made additives are also used - a hardening accelerator (for the production of foam concrete at temperatures above + 30 ° C or below + 15 ° C), fiber, expanded clay, etc.
2) Preparation of foam. The foam concentrate pre-diluted with water enters the foam generator. Here it foams under the influence of compressed air and, with the help of compressor pressure, exits through a foam-generating pipe into the mixer. The texture of the foam can be adjusted with special valves for exiting the pipe from the smallest (less than 0.1 mm) to large pores.
3) Production of foam concrete mix. Sand is poured into the mixer, then cement, the mixture is thoroughly mixed (the quality of the future foam concrete depends on the uniform distribution of sand in the cement). After the mixture is closed with water, kneaded until a plastic homogeneous mass is obtained. Foam is added to the mixer through the hose from the foam generator, actively mixed with the cement-sand substance for 2-3 minutes.
Barotechnology for the production of foam concrete
The cheapest (inexpensive equipment, less time-consuming) and widespread technology in Russia for the production of foam concrete. The essence of the method lies in the porosity under overpressure mixtures of all raw materials in a high-speed foam mixer. Foam concentrate and water are dosed by volume, cement and sand - by weight (or a specially made dry mixture of dry foam concentrate, cement and sand is dosed by weight). All components are fed into the foam concrete mixer, where air is pumped by the compressor, creating pressure inside. According to this method, air-entraining surfactant additives are introduced into the mixture and a special hermetic mixer is used.
The foam concrete mixture obtained in the foam concrete mixer is transported from the mixer under pressure to the place of laying in molds or a monolithic structure, where it swells as a result of pressure difference.
Significant disadvantages of barotechnology for the production of foam concrete is the low strength of products obtained by this method. The decrease in this indicator is due to the addition of a large amount of water to the mixing composition during production. If the amount of liquid is reduced, then full hydration of the cement will not occur.
Equipment used: two main types Russian installations Sunny and Fomm-Prof. Sunny installation designed for the production of foam concrete mixture without the participation of a foam generator. The volume of manufactured products ranges from 20 to 40 m³ per day. The advantages of Sunny are its relative cheapness and ease of use. The disadvantages include high costs for the foaming agent, small production volumes and poorer product quality.
Fomm-Prof installation. The principle of operation is to apply the classical method. The protein foaming agent comes as an additive. First, water, cement and sand are mixed, into the resulting cement mortar foam is added from the foam generator. The resulting foam concrete is distinguished by its strength and good quality, and also corresponds to GOST. The output per day is 60 m³ or more.
Porous foam concrete production technology
Porous technology is based on mixing cement-sand mortar and foam in a small high-speed mixer. It is used for pouring directly at the place of its pouring: on the object, into the floor, voids, roof. The processes of preparation of the initial solution and its porization are separated in time and space. There is a better hydration of the binder, there are no traces of a foaming agent in the initial solution. Only on porizers is it possible to obtain ultra-light foams in industrial scale with enhanced strength properties.
For preparation, mobile units are used (a solution of sand and cement is prepared separately, water is supplied by a pump, a foam is produced by the porizer, which interferes with the solution and the finished mixture of foam concrete is poured through a hose into the prepared form for solidification).
Dry mineralization technology
The technology of dry mineralization consists in the preliminary preparation of low-expansion foam with its subsequent combination with a dry cement-sand mixture. This technology has a good opportunity to work at a low water-solid ratio W/T (less than 0.5) and a low foaming agent content (0.2 - 0.4% by weight of the binder) without loss of quality. The complex process of foam generation is greatly simplified - low-expansion foam can be easily prepared on any primitive equipment. The density of foam concrete is easily regulated by the amount of foaming agent and the foam ratio.
The main difficulty of the industrial application of this technology is the need for preliminary grinding of the cement-sand mixture. This problem can be solved by some practical methods, which makes the technology quite applicable for monolithic castings at the site.
In monolithic works using the dry mineralization method, cavitation or baro-cavitation mixers are most often used. Of course, the technology of dry mineralization requires its own composition of components and a different batching schedule.
As a foaming agent for dry mineralization technology, it is recommended to use saponified wood resin; sometimes it is necessary to use a synthetic foaming agent.
You watched: Foam concrete production
To date, the production of foam concrete blocks is the most popular among the production of lightweight cellular concrete, this success is explained not only by the simple technology for manufacturing foam blocks, but also by the output of a high-quality and, in a sense, unique product. Only such products contain the positives of all traditional materials used for centuries in private and civil construction, so how is it possible to create such a versatile building material?
Production technologies
Foam concrete blocks can be produced by two technologies: casting and cutting, it also happens as autoclave hardening and natural exposure. During autoclave hardening, the foam concrete mixture is aged in special dryers - chambers at a set humidity and temperature, so, first things first.
Casting
Distinctive features this production technology - the finished mixture is poured into pre-prepared forms, the sizes of such forms can be varied. It is possible to withstand foam blocks with this type of their manufacture both with the help of a steaming chamber and in natural drying. An autoclaved foam block is considered to be of higher quality, but if you create optimal conditions in the place of exposure, you will get a no less high-quality product.
A concrete mixer, but not ordinary, but special, its secret is in obliquely arranged blades, which prevent foam from breaking during mixing. A hose for supplying the mixture or a special container with a volume equal to one batch, but for its movement around the workshop you will need a beam crane, a steaming chamber or a place to hold them, a plastic film. The best option is to purchase a special mini-factory as a whole, it will avoid a large number of marriages. As a rule, such a plant goes detailed instructions, and the selection of the composition of the foam concrete mixture of various densities, at some enterprises selling such equipment, field specialists are attached to it, who are adjusting the process. In the future, the production of blocks through such factories will minimize the rejection rate due to 80% automation of the production process.
Raw material
Most a good option, combining the principle of "price - quality" - this is cement M 400 D 20, only if it fully confirms its brand in quality, otherwise it is not a durable foam block.
Sand
Fineness modulus 0.02, no debris and foreign bodies, it is important that it has a moisture content of no more than 5%. If the indicator is higher, then before letting it into the construction site, you need to dry it thoroughly. The fact is that when mixed, the sand gives up this moisture to the mixture, the water-cement ratio increases accordingly, and there can be no talk of a high-quality mixture under such circumstances.
Which one is more suitable for your production depends on the type of equipment.
Water- conventional plumbing
Reinforcing element to avoid cracking.
The optimal selection of the composition of the mixture is revealed empirically, in order to identify a high-quality mixture, it is necessary that it has the following data:
- Assembling and lubricating molds, for these purposes, you can use ordinary used engine oil. It is better to lubricate with a spray gun, so the lubricant layer will be as thin as possible.
- Preparation begins with mixing water and fiber, if it is already added to the concrete mixture, the fiber will not completely dissolve, and the reinforcement effect will be weak.
- Next, cement is added to the mixer first, then sand.
- While mixing is in progress, we prepare the concentrate, for this we add to the finished foaming agent required amount water, mix and pour into a special container of the foam generator.
- After homogeneous mixing of cement with sand, we generate foam, it is important to ensure that during the application it is homogeneous and stable.
- Everything is mixed for no more than 3 minutes, the main thing during this time is to achieve a homogeneous mixture.
Form Fill
You can use the auger supply of the mixture through a hose, or you can use a bucket, in the first case, the auger blades break the foam and there are losses not only in the volume of the finished mixture, but also in.
aging
At autoclave production- no more than a day, but with natural drying, in order to make foam concrete more reliable, it is recommended to wrap the forms with insulation and cover with plastic wrap. On average, exposure is a day.
Demoulding of products and storage in the curing place
After 2 weeks of drying, the blocks are stacked on pallets and sent for sale. Many neglect this stage, but in vain, if fresh foam blocks are immediately put into construction, then under load they can give a stunning shrinkage or partially collapse.
cutting technology
It differs from the previous one in the way the mixture is poured. The finished foam concrete is placed in one large formwork, where it gains its initial strength, after which this monolith is freed from this form and cut into blocks with a special machine. In all other stages of production, both technologies are identical.
Production of foam block, video
Conclusion
The main principle of the production of foam concrete blocks is compliance with all the rules of technology and quality standards. Indents from them are fraught with low-quality products and a high percentage of defects.
Foam concrete production technology
The popularity of foam concrete has increased significantly in the implementation of construction activities. Buildings constructed from foamed concrete are different a high degree thermal insulation, provide a comfortable temperature regime of the room. The production of foam concrete is carried out at a growing pace, which allows us to meet the requirements of developers as much as possible.
Currently, the products are in demand in the market of building materials and are used in the construction of cottages, country houses, redevelopment, insulation of premises. Briefly describe foam concrete, it is a hardened array, including foam concentrate, Portland cement and water.
Foam concrete is a type of concrete that has a cellular structure.
The technological process of manufacturing a composite is quite simple, but it requires certain knowledge. For beginners who have not encountered the production of this material, the manufacturing process presents some difficulties. The development of production requires significant financial resources to create a high-quality composite.
The foam concrete production technology is based on the use of high-quality raw materials, the performance of work using special equipment. This contributes to cost-effective, high-quality products that meet customer requirements.
Components for the preparation of the foam mixture
The production of foam concrete blocks is carried out according to recipes that regulate the percentage of ingredients depending on the required density of the composite. All types of recipes include the following components:
- Portland cement, marking M400 and above. Increasing the grade of cement improves quality characteristics foam composition.
- Aggregates, which can be used large fractions of expanded clay, doubling the strength of the porous composition. The use of fine sand provides a density of 0.6 t/m³. More preferred river sand, having a size of up to 0.2 mm, which does not contain foreign inclusions. It is not allowed to exceed the clay concentration by more than 3%.
- Water, the percentage concentration of which is determined by calculation. Prior to the introduction of foam, the ratio of water and cement should be at least 0.38. A decrease in the water-cement ratio causes an increase in the volumetric weight of the product. This is because the concrete absorbs water, partially breaking up the foam, causing it to decrease. The optimal proportion of the ratio of water to cement is 2:5. The water temperature should not exceed 25 degrees Celsius.
- Foaming agent, which is used as a foam concentrate based on protein, bone glue or pine rosin. The shelf life of the composition should not exceed two to three weeks from the date of preparation. The temperature regime during storage is in the range from 5 to 30 degrees Celsius.
Foam concrete, the technology of its manufacture is so simple that, if desired, it is easy to reproduce even at home
Manufacturing methods
Methods for the production of foam blocks can be different. When deciding on the development of production, one should decide on a technology called:
- classical, in which foam is introduced into the pre-prepared cement-water composition, coming through the lines from the foam generator;
- barotechnology, which makes it possible to obtain a foam concrete composite without the use of a foam generator. The process involves whipping at a high frequency of the working body of the mixer abundant foam, into which sand and cement are introduced;
- porous, used for pouring a foam mass, filling voids, pouring ceilings directly in conditions construction site. Production is carried out using mobile units, which allow you to cook separately cement-sand mortar, pump water. The porizer produces high-quality foam supplied along the highway. At the same time, the finished foam concrete is fed into the mold through special hoses, where it solidifies.
Depending on the type of foam concentrate used and the technology adopted, the foam concrete preparation method is selected.
Classic technology
Let us consider in more detail the classical method of production, which is the most common method for the manufacture of foam concrete.
The production of foam concrete in the classical way provides for the following equipment and tools:
- Devices for mixing concrete.
- sifter.
- Connecting highways.
- Steam generator.
- Devices for dosing water.
- compressor.
- A set of precise molds for casting products.
- Loader for automated supply of raw materials or tools (buckets, shovels) for manual work.
Stages of work execution include the following stages:
- preparation of the necessary ingredients (cement M500, fine sand, water);
- preparation of a foamed mass by introducing a pre-diluted foam concentrate into a foaming agent container;
The prepared mixture is transported by means of a pump into a monolithic structure or mold
- production of foam concrete composition, for which sand and cement are loaded into the mixer, they are mixed until a uniform consistency is ensured. Then water is introduced and the prepared foam coming from the foam generator, which is intensively mixed with the cement-sand mortar for 3 minutes;
- molding products in pre-lubricated with a special molding compound containers where the foam concrete composition must settle for 12 hours;
- drying products after dismantling the formwork, extracting finished products on pallets. The final hardening of products is carried out in the room.
The duration of solidification of the array is determined by the temperature regime of the room and is:
- Two days at a temperature of 22 degrees Celsius. During this time, the products acquire up to 70% of the required strength.
- Eight hours if the temperature is maintained at 50 degrees Celsius during this time.
