Expanded clay blocks with their own hands. Features of the manufacture of expanded clay concrete blocks with their own hands

Since we were convinced of the manufacturability, reliability and practicality of this material. This article will talk about what expanded clay concrete blocks are and how to make them yourself, what are their features and advantages over other building materials.

You will learn about the production technology, how it is possible to make expanded clay concrete blocks with your own hands, is this process worth the time and effort.

Expanded clay concrete is lightweight, which allows you to create durable housing of a fairly presentable appearance, even on an insignificant foundation.

Expanded clay concrete- the only one with the most promising modern materials for construction. Its properties in terms of the speed of construction of various objects and the cost-effectiveness of its use significantly exceed the qualities of other materials.

Expanded clay structures are made exclusively from natural ingredients, and for this reason do not emit toxic substances into the environment. If you believe the reviews of those who built the house from expanded clay concrete blocks, they claim that very comfortable climatic conditions for living are established indoors.

Note. High-quality expanded clay concrete blocks have a density of 600 to 1800 kg/m3.

Production of expanded clay concrete blocks

Expanded clay concrete has unique properties determined by the peculiarity of their manufacture. Expanded clay is taken as a basis - an environmentally friendly material.

It has pores resembling a sponge in structure, in which there is a specially fired clay, which acquires the texture of a frozen foam. As a result, this material is very light and durable. Cement is used as a binder.

The strength and ability to retain heat depends on the correct proportions of the mixture. The more granules in the mixture, the more fragile the block becomes, but at the same time, the warmer, and vice versa.

Varieties of expanded clay concrete blocks

Expanded clay structures according to their own physical and technological data and purpose are divided into:

Density of heat-insulating expanded clay concrete blocks is the lowest. This type of expanded clay is made in a special way that promotes the formation of large pores. The density of such granules is 150-200 kg/m3.

Structural expanded clay has similarities with natural stone, which is why the walls of the house made of such material will be extremely dense. A significant advantage of expanded clay concrete over other building materials is the price.

The pace of installation of walls made of expanded clay concrete is 4 times faster when compared with brick buildings. In addition, when building houses from this material, 2 times less mortar is used, again when compared with brick.

The shape of expanded clay concrete blocks is complex, it has many voids-slits that improve heat retention in the house.

The desire to have a private house pushes people to look for cheap materials for construction. Expanded clay concrete blocks are just the material that is increasingly popular with developers.

The main feature of expanded clay concrete is that, in addition to the low cost on the market, it can be made by hand. We propose to consider the main nuances and tricks, as well as the composition of expanded clay concrete blocks in accordance with GOST.

What do you need to get started?

The manufacturing process is simple, the main thing is to adhere to the proportional ratio of components - 1:3:8. Water is added at the rate of 200 liters per 1 m3.

materials

Instruments

Manual machine for vibropressing

You can buy it in stores where they sell everything for construction. The approximate cost is 7 - 10 thousand rubles. You can also order from manufacturers. The design already has special molds for casting blocks. Also, the machine can be made with your own hands from an old engine and a metal worktop.

If you have the required number of molds and an extra pair of hands, about 150 expanded clay concrete blocks can be made per day.

In one working cycle, the machine produces 1 - 4 blocks. And if you assemble a team of several workers, the number can increase by about 2 times. Blocks can be made without equipment, the main thing is to choose a capacious container for mixing and pour into molds.

The molds for expanded clay concrete blocks themselves can be made of metal, plastic, wood (fasten with metal corners, sheathe them inside). To form voids in the blocks, some craftsmen use plastic bottles filled with water.

When mixing the solution, the exact amount of water is taken first. Sand, cement and expanded clay, sand are mixed, and then liquid substances (water, plasticizers) are introduced. In appearance, the mixture should turn out like softened plasticine.

Drying of expanded clay concrete

The final stage in the manufacture of blocks of expanded clay concrete is the drying of the finished product.

This takes approximately 2 days. In wet weather, the rocks increase.

Then the blocks are stacked on pallets in a row of 3-4 pieces. The finished blocks should not be exposed to sunlight and rain, it is better to keep them under a canopy. They are allowed to work in 1-1.5 weeks after production.

Drying for a month is the best option. Before laying, the blocks are cleaned of roughness and irregularities.

The cost of expanded clay concrete blocks do it yourself

According to some estimates, the approximate price of expanded clay concrete blocks will be about 20 rubles. For comparison, the price of finished ones is about 80 rubles. Savings, as they say on the face.

Do-it-yourself production of expanded clay concrete blocks

For the construction of capital buildings, private houses and temporary buildings, developers use compositions based on expanded clay. It is not always advisable to purchase them, which is associated with the need for delivery, financial costs and a number of factors. There is a way out of this situation! Do-it-yourself expanded clay concrete blocks can be made by preparing the necessary raw materials, tools, and special formwork in advance.

Expanded clay blocks are a promising material that has gained wide popularity among builders and private developers. Unlike traditional concrete, which consists of Portland cement, sand, additives and water, expanded clay composites use a completely different filler - expanded clay, which is clay balls that are fired in kilns during rotation using a special technology.

Expanded clay concrete is less dense than conventional concrete. However, this does not affect the strength of the manufactured products. The material attracts customers with an affordable price, which creates a steady demand among developers.

Varieties of expanded clay concrete

Expanded clay blocks are made from various types of concrete, differing in size, concentration of cavities in the array, representing air pores. Expanded clay aggregate concrete is classified as follows:

• composition with enlarged pores (large-pore);
• porous composite;
• compacted concrete.

Table of types and characteristics of expanded clay concrete blocks

Depending on the scope of application during construction activities, expanded clay blocks are divided into the following types:

• constructive and heat-insulating purpose;
• thermal insulation products;
• structural elements.

According to the classification, blocks of a composition filled with expanded clay can perform a heat-insulating function and, at the same time, absorb structural forces. The material is suitable for construction, construction of walls, characterized by increased thermal insulation characteristics and strength.

Advantages and disadvantages

Products with expanded clay filler have a number of advantages compared to other building materials, and are characterized by:

• Small weight due to high porosity.
• High soundproof characteristics.
• Ecological cleanliness associated with the use of natural raw materials.
• Increased thermal insulation, creating a comfortable microclimate of the room.
• The increased durability allowing to perceive considerable loadings.
• Low expansion coefficient preventing cracking;
• Frost resistance, allowing painless perception of deep freezing.

With many advantages, composites have minor disadvantages:

• problematic application in the construction of multi-storey buildings, associated with the peculiarities of the structure;
• narrow scope of use of products with cavities, caused by design features.

Manufacturing specifics

Do-it-yourself production of expanded clay concrete blocks requires practical skills, accuracy, equipment and the following materials:

• Portland cement;
• expanded clay filler;
• sand;
• wood, metal for the manufacture of formwork.

The main ingredient of the mixture is expanded clay filler of fine fraction

In addition to traditional cement, sand, as well as binding additives, the main filler is expanded clay, which is characterized by a high concentration of air cavities. The composite obtained as a result of hardening is used for planning concrete surfaces, insulation and has improved thermal insulation characteristics.

For self-manufacturing, follow the technological recommendations used in an industrial enterprise, involving the use of a vibratory compactor and drying.

The implementation of the main stages of manufacturing will require preparation. When mixing the composition, expanded clay floats. Ensure the flatness of the surface of the array by pressing into the filler mixture. The characteristics of the obtained elements will correspond to the parameters of expanded clay concrete, manufactured industrially.

Formwork preparation

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Use thin steel sheets and wood for crafting. You will need a pencil, tape measure, hand saw. Think it over. We advise you to focus on the dimensions of a standard cinder block and brick. It is preferable to reproduce the geometry of a brick, but for a large building it is more convenient to use an increased size corresponding to a cinder block.

Formwork for pouring 48 expanded clay blocks at a time

The main stages of the construction of the form:

• Mark the blanks of the required dimensions.
• Cut out the necessary details.
• Prepare L-shaped side elements.
• Connect the elements of the workpiece using steel corners.
• Nail a thin sheet of metal to the base and sides of the formwork.

In the absence of sheet material, use machine oil, which is coated on the inside to ensure tightness.

Materials and equipment

Having built the formwork, prepare the equipment, materials for work and start making expanded clay concrete blocks with your own hands. The quality of materials determines the strength of products. They should not stick to the mold surface. For manufacturing, you will need a vibration device, a device for mixing concrete.

For quick and continuous mixing of expanded clay concrete mix, you will need a concrete mixer

Also, prepare:

• standard expanded clay filler;
• river sand;
• technical water;
• Portland cement M400;
• a metal sheet substrate;
• plasticizing additives that ensure the strength of the product;
• wide spatula.

Composition preparation

Expanded clay products are easy to make on your own. It is important, adhering to the recipe, to prepare the solution.

Table of the composition of mixtures for the manufacture of expanded clay concrete blocks

Follow the steps in order:

• Mix Portland cement with expanded clay and sand in a ratio of 1:6:3. Make sure the solution is homogeneous.
• Pour technical water into a container, add a plasticizer, following the recommendations of the instructions.
• Mix the composition with the dry mix using a concrete mixer or a hand mixer.

The result of the operation is to obtain a uniform thick mixture, the consistency of which corresponds to the density of sour cream. Properly prepared solution hardens quickly.

casting technology

Carry out the casting process using special equipment. You will need a concrete mixer, the volume of which is 130 liters, as well as a vibrating machine, which is a base with a vibrator fixed on it. On the body of the machine are fixed containers for molding, which are filled with the composition.

Fill the blocks with your own hands, following the recommendations:

• Perform work at a temperature of 15-20 ° C in a spacious room with a flat floor surface, which affects the flatness of the product base.
• Install the blanks for forming the cavities, keeping an equal distance between them. If you are building a large building, then it is advisable to use elements without cavities.
• Pour the composition using a trowel, scoop or spatula. Quickly fill the formwork so that the mixture does not have time to harden. Stop filling when you fill out the form.
• Let the composition harden for 3 days.
• Remove the hardened element from the mold by lightly tapping the surface.

The finished product has the correct geometry without sharp edges. Remove minor irregularities using a cutting tool. In case of serious defects, do not use the product for construction work. Inspect the form, eliminate defects.

The manufacture of expanded clay concrete blocks with your own hands can be accelerated using several formworks. By producing products in small batches, you will reduce the lead time, quickly receive the material for the construction of the building.

The production of expanded clay concrete blocks can be organized at home. To get the finished product, the master will have to purchase the appropriate equipment and high-quality raw materials. If you are preparing expanded clay concrete with your own hands, the proportions must be observed with maximum accuracy.

For the production of material, the master will need a concrete mixer and a vibrating machine.

Manual vibrators

The small-sized device is optimally suited for the implementation of work in non-professional conditions.

Main characteristics:

• the vibrator is fixed on the body and produces moderate vibrations, which ensures a uniform distribution of the working mass in the form;
• the product is equipped with stationary and removable void formers. In the first case, it is possible to produce solid and hollow modules;
• depending on the manufacturer and additional options, the cost of the vibrator reaches 10 tr.

The use of special equipment will ensure high quality of the finished block, but can be costly for private construction

Mechanized mobile machines

Main characteristics:

• the equipment is completed with a bearing body and a lever drive for automatic removal of the form from the body;
• the machine is equipped with wheels that allow you to organize easy movement around the site;
• depending on the needs, you can choose a model with various add-ons, for example, a tamping press;
• the vibrator is fixed on the device and sends an impulse to the form;
• the device can be equipped with 4 matrices, which speeds up the production process;
• the cost reaches 16 tr

vibrating table

Main characteristics:

• the base of the device is equipped with a built-in vibrator, a metal pallet is placed here, up to 3 mm thick;
• molds are placed on the pallet, which are rammed with vibrations;
• then the pallet is taken to a ventilated dry place where the final drying of the material occurs;
• all manipulations are carried out manually;
• up to 6 forms can be prepared at a time, which are conveniently transported on a pallet to the place of drying;
• the lower placement of vibrators allows you to get a complete and optimal distribution of vibrations throughout the table;
• the cost of equipment fluctuates around 20 tr;
• the vibrating table is not mobile, large-sized and requires a lot of manual labor.

vibropress

Equipment of this class is used in large factories and enterprises. At all stages of manufacturing blocks, manual labor is practically excluded. The device is characterized by high performance and allows you to get excellent quality modules.

For mixing the mixture, a concrete mixer is used, with a volume of at least 130 l

Form preparation

Forms can be made by yourself using a plain wooden board, 20mm. The design is formed on the basis of a pallet and two l-shaped elements, which, when assembled, form boards or 4 standard boards.

The product can be designed for the manufacture of hollow or solid modules:

• forms without voids;
• forms with through voids;
• forms with blind voids.

The parameters of the product must ensure the manufacture of the required dimensions of the expanded clay concrete block. Inside the form is sheathed with metal. An alternative would be to make molds entirely out of metal. This will ensure easy removal of the finished block.

Expanded clay concrete - composition

Below are a few recipes that can be used to prepare the working mixture.

Recommended composition of 1 m³ of concrete for the manufacture of wall stones:

• Portland cement M400 - 230 kg;
• expanded clay gravel, fraction 5.0-10.0 mm, density 700-800 mg / m³ - 600-760 kg;
• quartz sand, 2.0-2.5 mm - 600 kg;
• water - 190 kg.

If you use the specified recipe, you can get concrete grade M150, with a dry concrete bulk density of 1430-1590 kg / m³.

To increase the resistance of expanded clay concrete to the action of water, some aggressive environments and freezing, you can use the indicated recipe for 1 m3:

• cement - 250 kg;
• expanded clay mixture - 460 kg;
• expanded clay sand - 277 kg;
• W / C - the ratio of cement and water - is taken as 0.9;
• Bituminous emulsion - 10% of the mixing water volume.

Before work, the bottom of the mold is sprinkled with sand, the sides are treated with machine oil

How to prepare expanded clay concrete with your own hands based on 100 kg of working mixture:

• expanded clay - 54.5 kg;
• sand - 27.2 kg;
• cement - 9.21;
• water - 9.09 kg.

From the specified number of components, 9-10 hollow modules can be made.

How to make expanded clay concrete without a dispenser? If we take a bucket as a volume unit, it is permissible to use the following proportions:

• cement M400 - 1 unit;
• sand, cleaned, 5 mm - 2 units;
• expanded clay, with a density of 350-500 kg / m³ - 8 units;
• water - 1.5 units. – the final liquid content is determined on site, depending on the consistency of the resulting solution.

Preparing the mixture

How to make expanded clay concrete, the proportions of which are selected and ready for mixing? For operation, a forced mixing mixer is used, which does not allow changes in the particle size distribution of expanded clay grains and their destruction.

The duration of the kneading depends on the vibro-placement of the solution and is 3-6 minutes. Due to the fact that claydite concrete quickly loses its workability, it is permissible to keep it in the mold after preparation until compaction for no more than 30 seconds.

The sequence of laying the components in the concrete mixer:

• water;
• plasticizer - if used;
• sand, after which the mass is thoroughly mixed;
• the entire volume of expanded clay is gradually introduced;
• cement.

When kneading, the gravel should be covered with cement mortar. The mass must be homogeneous.

It is convenient to dose the material with volumetric dispensers, which will ensure the optimal granulometric composition.

With longer exposure, the strength of expanded clay concrete can be lost, which is dangerous in the production of material intended for wall structures.

How to make expanded clay concrete blocks yourself, video

Works can be implemented with or without special equipment, which affects the quality of the finished module.

If you need to make expanded clay concrete blocks with your own hands, the finished working mixture is molded:

• a stainless steel plate is placed on the vibrating machine in a special recess;
• expanded clay concrete is poured onto the plate;
• vibration tightly distributes and compacts the mixture;
• excess is removed with a trowel;
• the plate with the formed mass is moved to the dryer.
• drying is the final step. The blocks, being in steel plates, dry for 48 hours. After that, the plates are removed and the process continues in the open air until fully ripe.

If the master does not have the appropriate equipment There is another way to make blocks:

• the form is installed on a flat metal surface;
• the formwork is filled with mortar;
• the mixture is rammed with a wooden or metal bar, but it is best to implement this process on a vibrating table;
• when the cement milk is released, the top of the module is leveled with a trowel;
• the form is removed after 24-48 hours, the blocks are left until fully ripened.

Expanded clay concrete, composition for the floor

The selection of the proportions of expanded clay concrete for the floor depends on the operational load of the coating. If the arrangement of floors for domestic purposes is implied, it is advisable to use the indicated recipe:

• cement M500 - 263 kg;
• water - 186 l;
• sand - 1068 kg;
• expanded clay - 0.9 m³.

A standard concrete mixer is used to prepare the working mass. Manual mixing is difficult to achieve uniformity of the working mass

For expanded clay concrete, the proportions for the screed may vary. The following recipe is considered no less effective:

• cement-sand mixture - 60 kg;
• expanded clay - 50 kg.

For the preparation of a cement-sand mixture, the ratio of components is taken as 1: 3, for example, 45 kg of sand will require 15 kg of cement.

The proportions of expanded clay concrete for the floor allow you to choose the grade strength of the material. The following are the proportions relative to the content of expanded clay, sand, cement:

• 7 / 3.5 / 1.0 - M150;
• 7 / 1.9 / 1.0 - M300;
• 7 / 1.2 / 1.0 - M400.

How to make expanded clay at home

The principle of the technological process is the firing of clay raw materials, according to the optimal mode. The most economical production method is the dry method. It is advisable to use it in the presence of clay stone-like raw materials - clay shale or dry clay rocks.

According to the technology the raw material is crushed and redirected to the rotary kiln. If the material contains too small or large pieces, they are screened out. The latter can be further crushed and launched into the production process.

The master needs to understand that the organization of the process will require the purchase of equipment and the method justifies itself if the original rock is homogeneous, has a high swelling coefficient and does not contain foreign inclusions.

Basic equipment:

• fine and deep grinding rollers, stone-releasing rollers;
• drying drum;
• kiln for roasting;
• molding unit.

The production of expanded clay is very energy intensive, therefore it can be deployed at home only if there is free fuel

The question of how to make expanded clay concrete blocks yourself worries many beginners and experienced builders. The recommendations provided will help you understand the progress of the work.

How to make expanded clay concrete blocks yourself is shown in the video:

Developers began to use expanded clay concrete with pleasure, as they were convinced of the manufacturability, reliability and productivity of this material. This post will tell you what is expanded clay concrete blocks and how to make them yourself, what are their specifics and advantages over other building materials.

Learn about production technology, how it can be done expanded clay concrete blocks with their own hands, whether this process requires effort and time.

Expanded clay concrete is distinguished by its low weight, which makes it an excellent opportunity to create a solid dwelling of a fairly presentable appearance, even on an insignificant foundation.

Expanded clay concrete– the only one with very promising Heading 1 (60 characters):

caption of today's building materials. Its properties in terms of the speed of construction of various objects and the economy of use significantly exceed the qualities of other materials.

Expanded clay concrete constructions are made only from natural elements, and due to this they do not emphasize toxic substances in the surrounding environment. If you trust the impressions of those who built the house from expanded clay concrete blocks, they say that the most comfortable climate conditions for living are set in the room.

Note. Very high quality expanded clay concrete blocks have a density from 600 to 1800 kg/m3.

Production of claydite concrete blocks

Expanded clay concrete has unique properties, specific to the specifics of their manufacture. Expanded clay sand is taken as a basis - an environmentally safe material.

It has pores resembling a sponge in structure, in which there is intentionally burned clay, which acquires the texture of a frozen foam. The result is a material of this kind that is the lightest and most durable. Cement is used as a binder.

Reliability and ability to keep heat depends on the correct proportions of the mixture. The more granules in the mixture, the more fragile the block becomes, but at the same time, the warmer, and vice versa.

Varieties of expanded clay blocks

Expanded clay concrete structures according to their physical and technological data and purpose are divided into:

1. insulating;
2. structural and heat-insulating;
3. structural.

Density of heat-insulating expanded clay concrete blocks is the smallest. This type of expanded clay sand is made in a special way that promotes the formation of large pores. The density of such granules is 150-200 kg/m3.

Structural expanded clay sand has a resemblance to a real stone, which is why the walls of a house made of a material of this kind will differ in incredible density. The big advantage of expanded clay concrete over other building materials is the price.

The rhythm of the process of installing expanded clay walls is 4 times faster compared to brick buildings. Moreover, during the construction of houses from this material, 2 times less mortar is used, again when compared with brick.

The shape of expanded clay concrete blocks is difficult, it has many voids-slits that improve heat saving in the house.

The desire to have a private home pushes people to look for inexpensive building materials. Expanded clay concrete blocks are exactly the material that is increasingly in demand among developers.

The main feature of expanded clay concrete is that, in addition to its low cost on the market, it can be made with your own hands. We recommend considering key invisible points and tricks, as well as the composition of expanded clay concrete blocks in accordance with GOST.

What is needed to get started?

The production process is simple, the main thing is to keep the proportional ratio of elements - 1:3:8. Water is added at the rate of 200 liters per 1 m3.

materials

Instruments

Manual machine for vibropressing

You can buy it at points of sale where they sell everything for construction. Estimated price 7 - 10 thousand rubles. You can also order from manufacturers. The design already has specialized forms for the visor of the blocks. Also, the machine can be made with your own hands from an old motor and a metal worktop.

If you have the right number of molds and an extra pair of hands, approximately 150 blocks of expanded clay concrete can be made in one day.

For one cycle of work the machine creates 1 - 4 blocks. And if you assemble a team of several workers, the number can become approximately several times larger. Blocks are allowed to be made without equipment, the main thing is to choose a capacious container for mixing and pour into molds.

The molds for expanded clay concrete blocks themselves can be made of metal, plastic, wood (fasten with metal corners, sheathe them in the middle). To form empty spaces in the blocks, some craftsmen use plastic bottles filled with water.

When mixing the solution, the exact amount of water is taken first. Sand, cement and expanded clay sand, sand are mixed, and then liquid substances (water, low molecular weight organic substances) are introduced. The mixture should look like soft plasticine.

Drying concrete from expanded clay

The final stage in the manufacture of expanded clay blocks is drying the finished product.

This takes approximately 2 days. In wet weather, the rocks become larger.

Then the blocks are placed on pallets in a row of 3-4 pieces. The finished blocks should not be exposed to the rays of the sun and rain, it is better to keep them under the ledge of the roof. They are allowed to work in 1-1.5 weeks after creation.

Drying for four weeks is considered a very good option. Before laying the blocks, they clean the roughness and irregularities.

The cost of making claydite concrete blocks with your own hands

According to some estimates, the estimated cost of expanded clay concrete blocks will be about 20 rubles. To compare the price of ready-made - about 80 rubles. Savings, as they say on the face.

Cinder block production technology

Expanded clay, as a bulk insulation, is used not only for thermal insulation measures related to the insulation of floors. It is often used for the production of concrete blocks, where it acts as a filler. From this, the blocks become light, because expanded clay is several times lighter than gravel or crushed stone, which it replaces in expanded clay concrete blocks, plus the thermal conductivity of the wall material itself decreases. The manufacture of expanded clay concrete blocks is no different from ordinary concrete blocks, the main thing is to strictly follow the recipe of the mortar used.

Let us designate the composition of expanded clay concrete for the manufacture of blocks based on 1 m³ of the prepared solution.

The above recipe corresponds to M150 concrete, which is sufficient for the assembly of wall structures.

Today, much attention is paid to such characteristics as moisture resistance. Therefore, in order to produce blocks of expanded clay concrete, which could easily withstand high humidity and even direct exposure to water (for example, oblique rain), waterproofing materials are added to the solution. One of them is bituminous mastic, which is closed as a 10% aqueous solution.

It should be noted that this solution has a slightly modified formulation.

There are different approaches to the production of expanded clay concrete blocks. A production line with powerful equipment and high productivity, where dispensers are installed, set to weight limits exactly according to the recipe. The second is the manual method, where the components are weighed more often in buckets. Therefore, it is worth indicating the weight of materials in buckets (10 l):

• cement - 13 kg;
• sand - 16;
• water - 10;
• expanded clay (gravel) - 4-4.5;
• expanded clay (sand) - 5.5-6.

Equipment for the production of

For the production of expanded clay concrete blocks (manually) you need:

• concrete mixer;
• several shovels;
• machine with a vibrator;
• several forms.

A concrete mixer can be purchased or rented. Machine tools are also sold, although these are not the cheapest equipment. You can make them yourself, and if you are a good welder, then one machine will take one day to assemble. Machine structures are huge. Basically, these are frame units, forms are installed and rigidly fixed inside. A vibrator is also rigidly attached to the frame, powered by a 220 volt network. The device is sold in hardware stores.

Another option is a vibrating table, which is a horizontal plane. It is usually mounted on springs, and a vibrator is attached to it. For the machine, you will have to make several forms with your own hands. And the larger the table area, the more forms will fit on it, the higher the performance of home-made equipment.

Important! Do not overdo it, because the vibrator has a certain power, which is enough to vibrate a certain mass.

Form for expanded clay concrete blocks

For the manufacture of molds, various flat materials are used: sheet iron with a thickness of at least 2 mm, boards, plywood, OSB boards, etc. The main task of the manufacturer of works is to adjust the dimensions of the form to the dimensions of the block: 190x188x390 mm (standard load-bearing wall block). There are so-called semi-blocks (used for the construction of partitions), dimensions: 90x188x390.

One of the features of expanded clay concrete blocks is voids, which lighten the stone without reducing the bearing capacity, reduce the cost by reducing the volume of the mixture used, and increase the thermal performance of the product. Therefore, during manufacture, three pipes with a diameter of 40-50 mm are rigidly installed in the molds, located at the same distance from each other and the walls of the mold.

Pipes are interconnected by welding with horizontal jumpers (reinforcement, angle or steel tape). They are attached to the walls of the mold by electric welding, if the mold is made of steel sheet, or with the help of self-tapping screws, if wooden products are used.

Production technology

The technological process itself is carried out in any room with a well-functioning ventilation system. The dimensions of the room depend on the dimensions of the machines used. Expanded clay blocks after manufacturing must undergo a drying process carried out in an open area on the street. If there is a possibility of precipitation, then it is better to erect a canopy over the site.

First of all, a solution is prepared: cement and part of the water are poured into the concrete mixer. The mixture is stirred for several minutes until a homogeneous composition is obtained. Then sand and expanded clay are added to it in portions. At the end, the rest of the water is added. The final solution should be thick and plastic.

After that, it is poured out of the concrete mixer into a container (trough) prepared in advance, and from there it is thrown with shovels into molds laid on a vibrating table or installed on a vibrating machine. Before this, the walls of the molds are coated with used technical oil so that the blocks can easily come out after hardening. The floor of the vibrating table or platform is sprinkled with fine sand so that the concrete does not stick.

Forms are evenly filled with a solution, for example, a couple of shovels thrown into them with a mixture. Then the vibrator is turned on, the concrete solution is evenly distributed over the entire volume of the mold and it is compacted. After which the process is repeated. This procedure is repeated several times to complete the forms completely. Sometimes, in order to give more accurate dimensions, the laid and compacted solution is additionally pressed on top with a metal cover; it will create a flat and smooth surface on the surface of the block.

In this form, directly in the forms, expanded clay blocks should stand for at least a day. After that, they are pulled out, laid on a street platform so that there is a gap between them within 2-3 cm. Blocks of expanded clay concrete should be dried for 28 days, which will give them branded strength. The material should dry on all sides evenly, so each block is turned over from side to side during drying. If you put them on wooden pallets to dry, then you don’t need to deal with coups.

Production of expanded clay concrete blocks as a business

It is not a problem to start producing claydite blocks in order to make a profit. The main thing is to accurately calculate everything. As practice shows, the main requirement is not for equipment, but for the size of the room and outdoor area. The larger they are, the more blocks can be laid for drying, which lasts about a month. Therefore, various drying options are offered. One of these is shown in the photo below, where special racks are visible with stacking blocks by floors.

Everything else rests on the cost of raw materials, which jumps depending on the season. In summer, cement is always more expensive, because the demand for it grows due to an increase in construction volumes. This is especially true for the private sector.

Therefore, it is optimal to produce expanded clay blocks during the autumn-spring period. If the room is heated, then production is not stopped in winter. Consumption of finished wall material in winter is small, sometimes it is reduced to zero, but in summer the entire produced stock of products will be sold out. Here it will be necessary to recalculate its cost at the new price of cement and other components. This is where the big profit lies.

Who is not the first year in this type of business trying to foresee everything. Someone is trying to purchase materials at a low price in winter, but there is a nuance - cement loses its properties over time, quality decreases. Someone, as described above, is trying to increase the production of blocks in the winter. In any case, this is a profitable business while construction is at its peak, as long as building materials are in demand. Expanded clay concrete blocks today are at the peak of popularity due to their low price, high thermal performance and ease of installation.