Characterized by increased strength compared to the rest. It is due to both the composition of the material and the peculiarities of its manufacture.
The production scheme includes several stages, each of which is served by a corresponding work module:
The capacity and type of equipment is determined by the scale of production. But in any case, aerated concrete can fully realize its qualities only when manufactured in an industrial environment.
The feedstock for aerated concrete production includes the following main ingredients:
The ratio of ingredients can be different, since it is produced in composition and in. Each ingredient is processed accordingly.
Provides mixing with ready-made technological foam, here a chemical reaction takes place inside the mixture during mixing and maturation. It is characterized by a sharp increase in the volume of the material.
In this area, aerated concrete stays for about 150 minutes, until it gains the hardness necessary for further stripping and cutting.
The movement of aerated concrete, which has not yet reached its design hardness, is allowed only in a rigid trough-like form. In this form, the material is transferred to the cutting machine.
The material is placed on a cutting carriage.
All cuttings are discharged into a sludge channel, which is periodically flushed with water.
The autoclave for the production of aerated concrete provides accelerated maturation of concrete at an increased pressure of 0.8-1.3 MPa and at a water vapor temperature of 175-191 C. under such conditions, chemical reactions continue to take place.
The accumulated finished blocks are loaded into an autoclave. As a rule, the material stays here for about 12 hours. Of these, it takes 1.5 hours to raise the pressure and temperature and 1.5–2 hours - to gradually reduce the pressure.
Processing time depends on the type of material:, density, and so on. However, if the aerated concrete, on the basis of which it was used, can reach the design strength without autoclaving, then in the case of this stage it is absolutely mandatory. The cost of an autoclave is from 290 thousand rubles. up to 4 million rubles
Production of this kind is offered in the form of a ready-made technological line of varying degrees of complexity and capacity. The cost, accordingly, will also be different.
There are two ways to obtain the material: with and without autoclaving. The first method provides greater strength and significantly reduces the production time, since aerated concrete gains its design capacity in 12 hours.
At the first stage, the raw materials are prepared: sand with gypsum stone is ground, water is prepared - it must be purified and heated to 40 C, other ingredients are heated if necessary: the temperature of the mixture in the mixer must reach 35 C.
Metallic aluminum reacts with a cement or lime mortar — essentially a calcium hydroxide solution — to produce calcium aluminates and large amounts of hydrogen. The latter, spreading over the mass of concrete, forms a huge number of small pores.
The process of autoclaved concrete production at the plant is captured in this video:
The production line eliminates the autoclaving step and is otherwise identical. Since it is the use of an autoclave that accounts for the greatest production costs, such a line is much cheaper both in cost and in maintenance.
Such material is not only less durable, but also gives a large shrinkage - up to 2-3 mm / m versus 0.3 mm / m for autoclaved aerated concrete. This problem is partially solved by the use of polyamide reinforcing fibers.
Let's talk about equipment for the production of autoclave and non-autoclave aerated concrete, and learn about the technology for making such a material with our own hands.
The production of non-autoclaved aerated concrete is discussed in the video below:
Produce aerated concrete blocks it is impossible without purchasing special equipment. A concrete mixer cannot replace a mixer, and adding metal aluminum by hand is extremely dangerous and strictly prohibited.
However, manufacturing companies offer mini-lines, in fact, consisting only of a gas concrete mixer and molds for aerated blocks. Moreover, the latter consist of small blocks, so that after swelling, the product no longer needs to be cut. The composition of the mixture is selected based on the needs. As a rule, it is still aerated concrete based on Portland cement. Experimenting with additives is undesirable.
The procedure remains the same as on the production line. The dosage, however, is carried out manually. Then the ingredients are mixed in the mixer, and the finished material is fed into the molds with a pouring hose. The stripping is carried out after the same 150 minutes.
The cost of such a line depends on the capacity. So, the installation for the production of aerated concrete METEM-GBS-250 costs 65 thousand rubles.
The production of autoclaved aerated concrete requires special equipment: a number of chemical reactions take place here, which require quite certain conditions... Non-autoclaved can also be obtained on mini-line equipment for the production of aerated concrete.
The technology for the production of aerated concrete at home is presented in the video below:
Aerated concrete production - an advantage home business+ technology. Making aerated concrete on an industrial scale - 8 key steps. A complete list of equipment for the production of aerated concrete at home and in production + 7 stages of development of the enterprise into a full-fledged business.
The world of building materials is improving every year. Hybrid products are born with high technical characteristics, which not only extend the life of buildings, but also save the consumer money. One of these innovations is the production of aerated concrete.
Today we will tell you in detail the manufacturing technology of this building material and how it stands out from competitors in general.
We all know about concrete - no construction can do without this material. Basically, its use occurs as a binder, but in combination with fillers (sand, crushed stone, etc.), it can be obtained, which are an alternative to bricks and shells.
Aerated concrete- one of the types of aerated concrete. Distinctive feature- the porosity obtained by chemical reactions during the production of the material.
There are many classifications of aerated concrete. They depend on the equipment on which it was produced and auxiliary additives.
The advantages of aerated concrete:
As elsewhere, there are also some drawbacks here. However, the main feature of this material is that these disadvantages can be leveled. To do this, simply adhere to elementary operating standards and use aerated concrete only for its intended use.
Disadvantages of aerated concrete:
The production of aerated concrete is a very popular direction, which has become widespread not only in industry, but also as a "handicraft" production at home. Fortunately, the technology is quite simple and the equipment for these purposes is very easy to get.
The main threat to business is the decline in the overall reputation of aerated concrete due to private producers who sell low-quality goods to their consumers.
There are two types of aerated concrete according to the manufacturing method - autoclave and non-autoclave. The structure of both the first and the second is similar, but the key difference lies in the technological aspect and equipment required for the implementation of production.
We have provided a comparative description of the two types of aerated concrete in the table below:
| Characteristic | Autoclaved aerated concrete | Non-autoclaved aerated concrete |
|---|---|---|
| Solidification | Processed on last stage manufacture in an autoclave. Impact high pressure and temperature gives its results. The finished product can be received in 24 hours. | Reaches brand strength in vivo. Sometimes it is slightly warmed up in special ovens to a low temperature not exceeding 100 degrees. This makes the process faster. The technical maturity of such products occurs after 28 days. |
| External characteristics | White + clear shape boundaries | Gray. Sometimes the corners of aerated concrete can crumble |
| Strength / density | More durable material. Strength and density are optimal for wall construction. | Less durable aerated concrete. In order to equalize the indicators with the autoclave, when erecting an insulating wall, it is necessary to increase the thickness of the masonry by 18-20 centimeters. |
| Brittleness, durability, geometry | Autoclaved aerated concrete can last up to 200 years, and thanks to the improved geometry, the amount of additional costs during construction is significantly reduced. | Hydration-hardened aerated concrete is more fragile. Its durability can reach 50 years. |
| Complexity of production | Autoclaved aerated concrete is produced, as a rule, using high-tech conveyor installations. As a result, the production speed is higher, the productivity is higher. | The production of non-autoclaved aerated concrete takes much more time, and when making products with your own hands, labor costs are extremely high. |
The production of aerated concrete by a non-autoclave way can be done at home, since there is no need to purchase full-scale equipment that works on the principle of a conveyor.
Autoclaved aerated concrete can only be produced industrially... For these purposes, full-fledged automatic production lines are purchased + this is all supplemented by other specialized equipment, which reduces the process of manufacturing aerated concrete within 18-24 hours.
Classification of aerated concrete based on density:
If you want to produce aerated concrete in accordance with GOST, you will have to indicate the category of your products, which already applies to the blocks themselves, which are obtained at the final stage of the production of porous concrete.
The figure above shows the complete classification of aerated concrete blocks based on their geometry and the technical characteristics of the building material.
If the production of aerated concrete takes place on manual equipment at home, it will be very difficult to adhere to all the requirements. However, the higher the quality of aerated concrete, the more expensive the product will be on the market. And this makes it possible to further expand the idea and switch to an industrial version of the production of porous concrete.
For the production of aerated concrete at home, no expensive equipment is required, most of the technological processes can be performed independently + savings for the end user will be about 40% of the market value of porous concrete.
Why is it profitable to make blocks at home:
Home-made aerated concrete can be used for the construction of 1-2 storey buildings, and the manufacturing process itself must be carried out at a temperature of at least 5+ degrees Celsius, otherwise the porous concrete simply cannot dry out normally.
Equipment for the production of aerated concrete at home:
Concrete mixer.
Manual mixing of the solution is not even worth considering as an option, since it will not be possible to ensure high-quality mixing of reagents and achieve uniform porosity.
Forms for filling.
If it is not possible to buy ready-made, it will not be difficult to build this equipment yourself. It is enough to have a sheet metal cutting machine at home, a welding and riveting machine for fastening elements.
Forms made of wood are also allowed, but for their production, joiner's equipment is required.
Steel wire.
It is necessary for cutting off the upper bumpy part of aerated concrete after filling the blank molds with a mixture.
As feedstock for the production of aerated concrete, concrete D20 -400, quartz sand and additives such as caustic soda and sodium sulfate are used.
To obtain porous concrete, 2 components must enter into a chemical reaction - quicklime and aluminum powder. All components are mixed and filled with running water.
Aerated concrete manufacturing technology at home:
Mixing dry components.
Adding liquid.
Water is poured in and the aerated concrete mixing process continues until the solution becomes completely homogeneous. The powder reacts with lime and air bubbles begin to appear inside the mixture.
It costs up to 20 minutes to mix on the equipment, but in some cases it can take longer. It all depends on the recipe for the production of porous concrete and on which unit the mixing takes place.
Filling forms.
The finished seven of the equipment is poured into prepared forms, but they are only half filled. The formation of air bubbles will cause the aerated concrete to expand, thereby filling the entire mold area to the very top.
Fitting blocks.
After 6-7 hours, aerated concrete will set and take on its final appearance. Excess porous concrete that has crawled out of the mold is cut off with a metal string.
Intermediate exposure.
At this time, aerated concrete remains in shape for 13-14 hours. Place the blocks under a canopy or in a room where the temperature is above 5 degrees, and also avoid getting moisture into the mold.
Final maturation.
Aerated concrete of non-autoclave production reaches its peak strength only after 26-30 days from the date of manufacture.
The very recipe for aerated concrete is selected based on the requirements that the consumer puts forward to the building material. If your goal is to get a high-strength material for building a building, be prepared to lose a few points in thermal insulation and vice versa.
Below we have provided one of the options for the distribution of proportions in kilograms:
There are also percentage tables - this option will allow you to calculate the correct proportions for the production of aerated concrete for any amount of raw materials.
Be prepared for the fact that your first pancake will become a lump - the technology for the production of porous concrete is not complicated, but it requires skills and an eye from the person who deals with it.
Practical tips for a beginner:
Recall: at home it is possible to use only non-autoclave method aerated concrete production. The duration of maturation of products is longer, but also corresponding.
The technology provides for both autoclave and non-autoclave methods of setting up production. Nevertheless, in 90% of cases, entrepreneurs prefer the former.
The advantages of industrial production of aerated concrete:
Industrial production is aimed at organizing a business, therefore, working in this area, an entrepreneur aims not at the private use of the obtained aerated concrete, but at its wholesale sale to the end consumer.
We will talk about the nuances of organizing a business a little below, and now let's look at the technology for the production of aerated concrete on an industrial scale.
The production of porous concrete consists of the following technological stages:
If the production is designed for the non-autoclave method, then after the 7th step, the finished porous concrete blocks are sent for drying to special heated rooms. The ripening period for blocks in this case ranges from 5 to 8 days.
Non-autoclave production of aerated concrete at the outlet gives a lower quality of the material, but there are methods to increase its resistance:
The non-autoclave or autoclave method does not matter. The only difference in the equipment list is the autoclave.
The minimum list of equipment for industrial production:
Required for batch feeding of solution components into the mixer. The price on the Russian market is from 130,000 rubles.
Mixer.
You can opt for specialized equipment specifically for aerated concrete or save up to 30% and supply a conventional mortar mixer. The price for a specialized version of the equipment is from 100,000 rubles.
Water dispenser.
Vibrating sieve.
It is necessary for sifting quartz sand and other dry mixtures. On an industrial scale, it will cost 50,000-55,000 rubles.
Steam generator.
It is used in the production of aerated concrete for the treatment of ready-made blocks with steam. Price - from 50,000 rubles.
Complex for cutting.
In the conditions of the plant, all stages of production are automated and personnel of 3-4 operators + a small team of transporters of finished products to the warehouse are used to control the process. We will dwell on this point in more detail below.
There are a lot of worthy conveyor solutions on the Russian market, so it may not be possible for a beginner to choose one thing on his own. Below we bring to your attention the optimal list of equipment for automated lines for the production of aerated concrete in a plant.
This price list is not a benchmark. Each of the companies has its own list of equipment, different brands and prices.
For a novice entrepreneur, the most important role will be to play out the cost, and this pleasure is not at all cheap - an automated line with a minimum set of equipment costs from 4,000,000 rubles.
Suppliers will not only help you with delivery, but will also advise on installation and layout in an industrial area.
By the way, the requirements for the factory premises are as follows:
Of course, do not forget about the height of the ceilings - from 500 centimeters. Lower ones can cause problems with the installation of some items of equipment, as well as when moving aerated concrete on transporters.
We suggest below that you familiarize yourself with other points of the business plan that will have to be taken into account in the work of any person who decides to connect his life with the world of investments in the production of building materials.
To establish a business, you will need to go through 7 stages.
The form of management is selected on the basis of a previously conducted analysis of the sales market.
If you plan to engage in the production of aerated concrete for large construction companies or international contractors, it is worth registering an LLC. In the event of a business failure, the state will be able to compensate part of the losses from the treasury, but also be prepared for high taxes.
When you pay taxes according to the ONS and you can more flexibly adjust your business plan, which is an undoubted advantage for a beginner entrepreneur.
Business registration features:
When registering an individual entrepreneur, indicate 3 OKVED codes - 26.61, 23.69 and 46.73.6. All of them relate to trade in building materials, namely, aerated concrete.
The package of papers is submitted to the authority or the MFC, where it is considered in a period of 10 to 15 working days.
To establish the production of aerated concrete, you will need to have at your disposal three premises - a workshop, a warehouse and an office.
A preliminary search should be started even at the stage of collecting documentation for registering a business, since in order to obtain permission from Rospotrebnadzor, you will need contracts for the lease of production and warehouse space.
The nuances of the selection of premises:
An area of at least 300 m2 + ceiling height from 5 meters. The more equipment is purchased, the larger the building will be needed.
Pay attention to the availability of high-quality electrical wiring and water supply, as well as the convenience of organizing the supply of raw materials and the export of ready-made porous concrete to warehouses.
The squareness depends on the size of the production. Do not rent areas with high humidity - aerated concrete will not be able to mature in such conditions with non-autoclave production, and if you place autoclaved porous concrete in a humid environment, it will begin to crumble.
Enough 20-25 m2 in the city center or industrial area. Check for basic amenities and determine what needs to be done on the premises.
Ideally, all three rooms should be close to each other. In this case, you will not only save on fuel, but also make life easier for the buyers of your products.
All the subtleties of this stage + the list of the equipment itself we have considered above.
It is necessary to establish the line 14-20 days before the start of production - this will help to identify problem areas and eliminate them in advance. Do not save money on equipment, because your business venture as a whole will depend on it.
Another important aspect of production. Before the final selection of suppliers, conduct a market analysis and weigh the pros and cons of each representative. Study the terms of delivery and clarify even the smallest details - one unnoticed asterisk in the contract can result in millions of dollars in losses in the future.
What raw materials for the production of aerated concrete will need to be purchased:
When purchasing raw materials from a supplier, ask for European quality certificates. Even with the correct technology for the production of aerated concrete with low-quality raw materials, in the end, you will get a disastrous result.
Depending on the level of automation of your equipment, the number of workers in the workshop can range from 4 to 15 people. The fully automated aerated concrete production line can be operated by only three skilled operators.
What employees will be required:
If you are an entrepreneur with accounting for you, then you can save money in one place.
It is better to hire operators with work experience, otherwise you will have to incur additional expenses on personnel training.
After launching the production line and gaining momentum, you will need to sell your products to the end consumer.
It is good when the market in your region is not overflowing with similar offers - aerated concrete will "go away" quickly. But what if you are not one of the first entrepreneurs to choose this kind of business?
How to promote your product:
Flexible pricing policy for the product will keep the demand for aerated concrete stable throughout the year.
During the active period of purchasing building materials, gradually increase prices and make small discounts at peak times. Red price tags have attracted and will continue to attract buyers, so this is a win-win.
Aerated concrete production as a business idea.
What equipment is needed? Production technology.
Analyze the state of affairs at least once every 3 months. You will be able to spot problems early on and nip them in the bud.
Expand the range of products and take care of the convenience of your customers - the aerated concrete delivery service to your home can give your reputation a couple of points and entice customers from competitors who do not have such bonuses.
Finally, we offer an approximate calculation plan of income / expense and the overall profitability of aerated concrete production.
The average cost of 1 m3 of aerated concrete in Russia is from 4,000 rubles, which means that with 22 working days per month and 8 cubic meters of aerated concrete produced per shift, an entrepreneur can receive 4,000 * 22 * 8 = 704,000 rubles / month. For the year the amount will be 8,448,000 rubles.
Now let's calculate the cost of raw materials and additional costs of the production workshop:
| Indicators | Amount for this year activities, rub. |
|---|---|
| Net income will be: | 5,256,000 rubles |
| Payment for the rent of the workshop premises | 240 000 |
| Payment utilities(electricity, water, gas, etc.) | 120 000 |
| Purchase of raw materials for the production of gas blocks | 1 200 000 |
| Wages of workers in the production department | 1 140 000 |
| Staff contributions to the FSS | 342 000 |
| Advertising and promotion costs | 60 000 |
| Scheduled maintenance and possible repair of workshop equipment | 60 000 |
| Potential additional costs | 30 000 |
| Gross income (before taxes) | 4 536 000 |
| Tax payments | 680 400 |
| Total: | 3,192,000 rubles |
Based on the calculations above, you will get a very tasty morsel, but this is only if your business develops according to an optimistic scenario. In practice, it is unrealistic to reach the reference values - a realistic or even pessimistic scenario awaits you, and this is 3,000,000 and 1,500,000 rubles, respectively.
Even so, the numbers are still large. Therefore, the production of aerated concrete is the type of business that is definitely worth doing, whether you are a beginner in the world of investments or already an experienced player.
The profitability of 50% says a lot - the payback can come in 5-7 months of work, which is a very high indicator for a medium-sized business.
We examined the production of aerated concrete from two points of view - the user and the entrepreneur. If your goal is construction, then it is more rational to make aerated concrete at home (saving up to 40%). If you are planning to enter the regional sales market, then autoclave automated production lines are at your service.
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Equipment for the production of aerated concrete is industrial complex nodes and mechanisms necessary for the manufacture of blocks from autoclaved aerated concrete (better known as aerated concrete), which has been acquired wide use v modern construction, thanks to its irreplaceable useful properties... Light weight, remarkable energy-saving and heat-insulating properties, relatively low cost, gained wide popularity of aerated concrete. Compact equipment for its production will help not only save money during construction, but also set up your own small business.
More recently, for the production of gas blocks, workshops of a large area were required, and the presence of bulky industrial installations... The development and implementation of new technological processes significantly simplified the production process and made it possible to manufacture blocks on much smaller installations for mass production.
Block making equipment
A person who decided to start producing aerated concrete blocks for his own construction, or supplying other real estate construction projects, had the opportunity to do this without investing significant funds. Now he can take advantage of several options for developing his own business:
Mobile plant for the production of aerated concrete blocks
The purchase of equipment for the production of aerated concrete blocks in any case is a rather profitable acquisition if a person intends to engage in the production of aerated concrete blocks seriously, both for building his own house and for selling his own products through retail chains.
Before deciding on the type of equipment necessary for certain purposes, you should sensibly assess your own capabilities, the presence or absence of suitable areas, the possibility of hiring workers, or using your family's forces, sources of cheap acquisition of auxiliary raw materials, and the real ways of selling ready-made blocks.
Experts recommend observing certain precautions when purchasing all components of the work kit separately. All equipment must be purchased from one supplier (this will be cheaper), and, preferably, from one manufacturer.
Otherwise, when starting work on the creation of aerated concrete blocks, certain inconsistencies in the acquired auxiliary mechanisms may appear.
Self-assembly of a mini-kit for production may turn out to be much less profitable and convenient purchase, but you still need to know what is usually included in the production kit:
Technical characteristics of stationary equipment, for example, the Inntech-100 Profi line:
For a mini-plant, for example, you need:
If necessary, such a kit can be supplemented:
The best option for establishing own production at the initial stage, there may be a mini-line. With a relatively low level of automation, it produces about 15 cubic meters of aerated concrete, and requires only two workers. It includes a mobile mixer, and all other forms are installed permanently.
If the process progresses successfully, there will be inexpensive suppliers of raw materials, and small wholesalers who will be interested in selling volumes, and set a low markup at points of sale, after a while, it will be possible to think about expansion.
To establish production, you will need a room with certain components. It should not be in the city center, where rental prices are always high, but it should not be located at a great distance, so that transportation costs do not eat up a certain part of the profit.
For any of the available types of production, there are certain standards for the footage and the number of utility rooms, but it is better to initially remove the area that assumes the possibility of painless expansion in the right moment... This is done in order to avoid tedious relocation during expansion, and not to lose suppliers and buyers due to a change of address.
Optimal for such production would be a warehouse that is not used for its intended purpose, or a rented workshop of a small factory. The purchase of a mobile unit for building your own home does not require any conditions for its installation. Upon completion of construction, it can be rented out, or sold to another developer. This will already be a simple profit.
According to statistics obtained from surveys of builders, a mobile unit can save more than a third of the costs usually spent on the main building material. In addition, construction is proceeding faster, since one block of aerated concrete replaces the laying of 30 bricks.
Mobile installation will help you save on construction
The prerequisites for the rented premises are the availability of electricity and a water source. And you will also need to take care of the certificate for the manufactured products, if they are intended for sale.
The amount of required ingredients and the cost of production will depend not only on the conscientiousness of the suppliers, but also on what kind of block brand is planned for release.
To start the production process you will need:
In a general simplified formula, the production of aerated concrete is reduced to the formula water + cement + lime and plus sand.
The undoubted benefit received from the purchase of a mobile installation for building their own home prompted a fairly large number of people to start such a business on a monthly basis.
Building materials in a modern environment are in great demand, and the profitability of such a production can be increased if you are engaged in the sale of your own products yourself. In order to decide on such a production, you just have to sit down and count everything in detail.
The larger the volume of blocks produced, the lower the transport costs and the wholesale price for large purchases. But, at the same time, there is also a greater consumption of electricity and water.
Therefore, the purchase of equipment for the production of aerated concrete blocks must be carried out after all the necessary calculations, and everything should be taken into account. But if there is a desire to work, and not sit with folded hands, then everything will certainly work out.
Aerated concrete is a porous material and belongs to aerated concrete, it is divided into autoclaved and non-autoclaved. Differences in terms of composition between them are minor, but in the manufacturing process, the difference is significant.
Aerated concrete components:
The better all the components are crushed, the stronger the aerated concrete is.
The very technology for the manufacture of aerated concrete consists in mixing fillers (cement and sand) with gas-forming additives (lime and aluminum powder). After mixing them, a chemical reaction begins between the aluminum powder and lime, with the release of gas - hydrogen. It is this gas that creates pores in aerated concrete, which provide good thermal insulation and light weight.
By changing the amount of gas-forming additives, you can achieve different density aerated concrete, that is, the more gas in the concrete, the lighter it is, respectively, the less its density and strength. On the building materials market, you can find aerated concrete with a density from D150 to D700.
Aerated concrete is good because the pores in its composition are very evenly distributed, which ensures the same strength and thermal conductivity throughout the entire thickness of the blocks.
After the process of gas formation and the initial setting of the mixture, the total mass is cut with a string into separate blocks of the required thickness. Further, the gas blocks are gaining strength.
If we are talking about autoclaved aerated concrete, then it necessarily goes through the autoclaving process. Autoclaves are large containers in which heat(160-180 C) and the pressure of saturated water vapor.
The autoclaving process lasts about 12 hours, and its task is to quickly set the strength of the aerated concrete. Ordinary heavy concrete gains 70% of its brand strength in about a month, but if the temperature is increased to 180 degrees, then strength will be gained 100 times faster.
This solves several problems at once: there is no shrinkage of the blocks, it does not take time for the strength of aerated concrete. Next, aerated concrete is packed in a protective film and delivered to customers.
Fresh autoclaved aerated concrete is very humid, water in it is about 30-40%. Due to moisture, its density is significantly higher than stated. Therefore, before finishing works laid out aerated concrete wall should dry out for at least two seasons.
Autoclaved aerated concrete has a higher strength than non-autoclaved aerated concrete.
In scientific terminology, autoclaved aerated concrete is called tobermorite - an artificial porous stone. Since stones are minerals, they are absolutely environmentally friendly. Aerated concrete does not emit any harmful substances and is not radioactive.
In terms of fillers, these cellular concrete are similar, the difference is in gas-forming additives. If in aerated concrete bubbles are formed due to escaping gas bubbles, then in foam concrete due to foam, which is added to the mixture separately. The problem of foam concrete may be its heterogeneity, that is, there will be more bubbles in one place, and less in another.
The process of making foam concrete is much easier, which is why it is produced in a garage. Confidence in the quality of factory autoclaved aerated concrete and its composition is much higher. The strength and geometry of autoclaved aerated concrete is better than that of aerated concrete.
Previously, it was possible to produce such a popular building material at large enterprises with special equipment for the production of aerated concrete blocks. Today the improved technological process made it possible to set up the production of aerated concrete at the enterprise or at home based on the required quantity, technological characteristics, and the availability of funds. Based on how the process is organized, stationary equipment, mini-factories or small mobile installations are purchased, with the help of which aerated concrete blocks are made of different density levels.
The production process of aerated concrete blocks does not cause difficulties.
The group of concrete products is characterized by a cellular structure. Gas bubbles occupy up to eighty-five percent of the volume, which allows the finished blocks to be light in weight.
The raw materials are mixed in a concrete mixer for five minutes, after which an aqueous suspension of aluminum powder is added to the mass, which reacts with lime. The process generates hydrogen, which forms numerous pores that evenly permeate the material.
As soon as the aluminum powder has been added, the mass is poured into special metal containers, and the swelling occurs already there. To accelerate the reaction, setting and hardening process, the semi-finished product is subjected to a vibration load. Uneven spots are removed from the mass, which begins to harden, with a wire string, the raw material remaining in the form is cut into pieces the right sizes... The production of gas blocks continues in an autoclave installation, after which the products are calibrated on milling installations.
The use of autoclave equipment in the technology of aerated concrete production occupies a special place, since the properties of the material are improved. Formed and divided into separate blocks, aerated concrete is sent to autoclave installations and subjected to twelve-hour treatment with water vapor.
This manufacturing method allows you to obtain a material that practically does not shrink, is characterized by the homogeneity of the structure, which has good performance for noise insulation and heat preservation.
The second option for the manufacture of aerated concrete is the non-autoclave method. Full hardening occurs under normal conditions, high-tech equipment is not required for production. In this case, it becomes possible to make gas blocks yourself.
The material will not differ in strength.
To obtain a cellular block, a mixture is used, consisting of the following components:
Consider the features of lines for the production of aerated concrete.
This type of equipment is different:
The usual scope of delivery includes:
The price of such equipment is high, reaching 55,000,000 rubles. The amount is serious, but the productivity of the line makes it possible to produce at least three hundred thousand cubic meters of material in one year.
To accommodate all the equipment, it will be necessary to prepare a site of about four thousand square meters.
If we compare which manufacturer of gas blocks is better, then as an alternative it is recommended to pay attention to the equipment that has been in use. There are some peculiar risks, but the cost of the line will be significantly lower.
Continuing the comparison of gas blocks from different manufacturers, experts advise purchasing a conveyor of the Inntech-100 type. The cost is up to 3,000,000 rubles, and the productivity is much lower.
The peculiarity of such a line is the immobility of the mixing plant. Forms are moved and filled automatically. The cutting complex is mechanical.
German lines for the production of blocks are very popular. They are highly productive and operate for a long period. The material on such equipment is of high quality.
Its cost is much lower than the first option. But in terms of productivity, the line will produce no more than fifty cubic meters of material per day.
The set includes raw material dispensers and belt conveyors that feed the components into the mixing unit.
Unfortunately, this kit is not considered fully automated. In order for it to function fully, several workers will have to be involved.
For the installation of the line, a room will be required, the area of which will be from five hundred square meters.
This type of equipment is great for beginners looking to make blocks for their own use. By the way, some experts make such equipment for aerated concrete with their own hands.
The line operates on a 220 W network, while other types of machines require 360 W. The production volumes are small - from two to ten cubic meters per day.
To set up a release building material at home, you will need certain tools for the gas block and equipment. Their minimum set consists of:
Following the instructions, it is quite possible to make a gas block with your own hands using such a set of equipment. A positive feature of this method is that it is possible to establish the production process directly at the construction site by installing a machine for the production of aerated blocks there.
Homemade gas blocks are inferior in quality to the material made in the factory.
We will consider this production process in more detail, we will understand its differences and advantages.
With the help of such processing, quality characteristics finished product. The process is as follows:
Let's compare two types of materials:
They start with the fact that a pencil case is hammered out of the boards. The bridges made in advance are inserted into it along the entire length, dividing the common frame into cells. To do this, use waterproof plywood. For it to be well fixed, cuts are arranged in the boards.
With their dimensions, the cells must correspond to the required block sizes. To speed up the production process, it is necessary to produce several forms of different standard sizes.
To prevent the mortar mass from sticking to the boards, they are treated with special compounds or machine oil diluted in water.
To mix the solution, you will have to buy a mixer, compressor and hoses. By the way, such an installation is used not only for a one-time production of blocks, but also for organizing a small-scale production.
In addition to the above, you will need a wire to cut off excess mortar.
If there is no dispenser, then you will have to weigh the raw material yourself. Here it is necessary to observe the accuracy of proportions so as not to violate the quality of the products.
All components are loaded in the correct ratio. This will accelerate hardening, increase specifications blocks. By the way, such proportions are observed not only for home, but also for factory production of the material.
The prepared mass is poured into molds, they are not filled to the brim, because the mixture will still swell. As a rule, filling is carried out up to half the volume.
Gas formation occurs. After that, it is necessary to remove the excess mixture. This work is performed five to six hours after pouring.
After fourteen hours, stripping is performed. It is recommended to gently knock on the walls of the molds to make the blocks come off. For a set of technical strength, the material remains on open area or stored indoors.
Remember that the first time around, the perfect material may not work out.
We figured out how to make a gas block. It remains only to decide on the amount of material, purchase everything you need and start the production process.
