Expanded clay blocks production on the water. Equipment used for the production of expanded clay concrete blocks. Optimal proportions for expanded clay concrete mortar

- a popular material, including cement, sand and expanded clay. A simple technology for the production of expanded clay concrete makes it easy to master the production of products. Having studied the technical process, you can make high-quality claydite blocks with your own hands, and then use the finished material for a garage or cottage. In the manufacture of blocks, there is no need to use special equipment. For mixing, use a concrete mixer, and the dimensions of expanded clay concrete blocks will be provided by collapsible formwork, which you can easily make from improvised materials.

Expanded clay blocks - composition, varieties and performance characteristics

Expanded clay blocks are very popular in the construction industry due to their thermal insulation properties, resistance to moisture, strength and environmental friendliness.

Ceramic block is a popular material including cement, sand and expanded clay

When planning to make expanded clay blocks with your own hands, you need to prepare the following ingredients that make up the composite material:

Portland cement marked M400 and above, which acts as a binder;
sifted and cleaned of foreign impurities sand used as a fine aggregate;
granulated expanded clay, added to the composition of the expanded clay concrete mixture, as a large filler;
modifying components that increase the performance of composite blocks.

Also, for the manufacture of blocks, water is required, which is added in small portions to the concrete mixer when mixing. The technology also allows the introduction of fiber fibers, which significantly increase the strength properties of the blocks. Distinctive feature blocks - a cellular structure associated with the introduction of light, porous, durable and environmentally friendly expanded clay granules into the working mixture.

Expanded clay products are classified into the following varieties:

heat-insulating, used as a heater;
heat-insulating and structural, used for the construction of walls;
structural, in demand in loaded building structures.

Expanded clay blocks are classified according to the following criteria:

Areas of use. Products are used for the construction of walls and the construction of partitions;
designs. Solid blocks are made, as well as products with internal cavities;
sizes. Dimensions of wall and partition elements are regulated by the requirements of the current standard.

Expanded clay blocks have high performance

Expanded clay blocks have high performance characteristics that distinguish them favorably from other building materials. The main properties of the block composite:

strength. The blocks are capable of absorbing forces from 5 kg for heat-insulating products up to 500 kg for structural products per square centimeter of area;
thermal conductivity. According to this indicator, the material successfully competes with wood, concrete and brick. The use of hollow claydite blocks allows to reduce heat losses;
frost resistance. The ability to maintain integrity during deep freezing increases with a decrease in the porosity of the blocks. The frost resistance of heat-insulating composites does not exceed 50 cycles, and for structural products, the indicator increases tenfold;
ability to absorb noise. Soundproofing properties increase with increasing porosity. Expanded clay granules included in the blocks provide elevated level sound insulation;
vapor permeability. Due to the ability of expanded clay concrete material to freely pass air vapor, a comfortable level of humidity is maintained indoors;
slight shrinkage. Expanded clay blocks manufactured in accordance with the requirements of the technology retain their original dimensions. Shrinkage of block material per meter of expanded clay concrete masonry does not exceed 0.5 mm;
ecological purity. The composition of expanded clay blocks includes environmentally friendly raw materials. During the operation of the products, there is no release of substances harmful to human health.

Other advantages of the blocks also include:

light weight with increased dimensions;
the ability to perceive significant effort;
small coefficient of linear expansion;
simplicity;
expanded range of products;
affordable price level.

With an increase in porosity, the soundproofing properties of the blocks increase.

Due to the rough surface of the blocks, adhesion to the facing compositions increases, which speeds up the finishing measures. Along with a set of advantages, the blocks have one drawback - it is problematic to use them for the construction of multi-storey buildings due to the peculiarities of the structure of the expanded clay concrete composite.

We plan to make blocks on our own - we prepare materials and tools

Having decided to make expanded clay blocks with your own hands, prepare necessary materials, working tools and equipment for the production of composite blocks:

ingredients for the preparation of expanded clay concrete mortar;
concrete mixer for mixing components;
shovels and buckets for loading feedstock into the concrete mixer;
vibrating table for efficient compaction of the mixture.

You will also need collapsible formwork for single or group pouring of products. Do-it-yourself molds for expanded clay concrete blocks are easy to make from sheet metal, laminated plywood or wood.

Making expanded clay concrete blocks with your own hands - the nuances of technology

The production of expanded clay concrete blocks with your own hands is carried out according to the following algorithm:

The inner walls must be lubricated with used machine oil.

Make collapsible molds for making blocks.
Purchase materials for the preparation of the working mixture.
Prepare tools and equipment.
Decide on the proportions of expanded clay concrete mortar.
Weigh the raw materials and prepare the working mixture.
Make product molding.
Compact the solution poured into the molds.
Dismantle the formwork a day after pouring.
Lay out the finished products to dry.

For an accelerated set of operational strength, the technology allows steaming blocks in special chambers. Thanks to the use of steaming, the duration of the production cycle is reduced, which is important in the manufacture of blocks in increased volumes. Consider the features of the implementation of the main stages.

Preparing a mold for expanded clay concrete blocks

Molding containers for the manufacture of expanded clay blocks at home are easy to manufacture at minimal cost.

Possible various options molding containers:

For the manufacture of expanded clay blocks, the form can be made independently

wooden, for the manufacture of which planed boards or laminated plywood are used. Wood has a limited service life, however, it will reliably serve for small-scale production of blocks;
metal, for the construction of which is used Sheet steel. The formation of internal cavities is carried out using tubular inserts. Steel molds last for many years, provided timely cleaning and lubrication.

The internal dimensions of the form are made in accordance with the dimensions of a standard expanded clay block. Prior to the start of production, a sketch of the formwork should be developed.

Perform further work on the construction of the mold according to the following algorithm:

Transfer the sketch dimensions to the material.
Cut formwork blanks.
Prepare two L-shaped walls.
Connect the workpieces using metal corners.
Fasten the base sheet to the bottom plane of the walls.

It is important to carefully consider the design of the mold to ensure that it can be disassembled. Applying used oil to the inner surface will facilitate the removal of finished blocks.

Optimal proportions for expanded clay concrete mortar

If you want to make blocks of expanded clay with your own hands, you should properly prepare the working solution.

The main binders are sand, cement and water.

To prepare one cubic meter of expanded clay concrete mixture with a density of 1.5 t/m3, you will need:

430 kg of Portland cement brand M400;
720 kilograms of expanded clay granules;
420 kg of millet sand;
140 liters of water.

Proportions of components for various kinds expanded clay concrete, differing in specific gravity, is easy to find on construction sites or in specialized literature. It is important to mix the ingredients evenly and get a solution of a creamy consistency.

We cast claydite blocks with our own hands

For casting blocks, it is necessary to fix the molding containers on the working table of the vibrating machine and fill them with expanded clay concrete mortar.

When performing work, it is important to adhere to the recommendations of professionals:

lubricate the walls of the mold with working off;
fill at a temperature of 16-19 ° C;
perform molding on a flat surface;
protect products from rain and sunlight.

It is necessary to pour the solution in one step until the formwork is completely filled and then level the surface with a trowel or spatula.

Care must be taken when removing blocks from the mold.

Consolidation of the working mixture

Properly performed compaction of the solution affects the quality of finished products. For tamping claydite-concrete mixture is used:

manual device for tamping;
vibrating table with electric drive.

The process of vibration compaction of the mixture poured into the formwork is stopped when cement laitance appears on the surface.

The final stages of manufacturing block products from expanded clay

Depending on the specific conditions, the curing process in the form lasts from one to three days. Then the following operations are performed:

the expanded clay block is removed from the mold by lightly tapping on the walls. When removing expanded clay blocks with your own hands, care should be taken to avoid cracking the blocks and preventing the formation of chips at the corners of the product;
products are stacked on pallets and sent to a closed room. layout finished products should be done in one coat and avoid impact loads.

The drying time of finished products is 28 days, after which the hardened expanded clay concrete composite is used for the construction of walls and partitions, as well as for thermal insulation.

Summing up

It is easy to master the production of expanded clay concrete blocks on your own by preparing the necessary building materials and carefully studying the technological process. Performing work on your own will reduce the amount of construction costs and produce high-quality building materials that are not inferior in terms of the characteristics of industrial products. Having decided to make expanded clay blocks with your own hands, consult with professional builders. They will always help practical advice and tell you how to avoid mistakes.

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 uniform distribution working mass in 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 finished block, but may 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 simple wooden board, 20 mm. 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 expanded clay concrete quickly loses its workability, it is permissible to keep it in the form 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 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 for outdoors until full maturity.

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, respectively optimal mode. Most economical way manufacturing is a 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:

This type of building material is made from cement, water, expanded clay and sand - quartz, enriched or expanded clay. The production technology is similar to the production of popular cinder blocks. Expanded clay blocks are also lightweight and have a standard size of 190x190x390 mm. Technological process their manufacture is simple, investments are required relatively small, so the business is one of the most attractive in this area.

Material Advantages

The installation of expanded clay concrete blocks is justified in the construction of civil and industrial structures. They allow you to build lightweight structures that have good thermal insulation.

The main advantages of expanded clay concrete blocks include:

lightness - compared to brick, the load on the foundation is 2.5 times lower;
75% less heat is lost and at the same time the blocks retain high strength;
they pass air well, while being resistant to the penetration of moisture and chemicals;
walls made of expanded clay concrete blocks do not require additional shrinkage and insulation;
allow you to quickly erect structures, which reduces the cost of work by 30-40%;
environmental friendliness;
frost resistance is kept at the level of 50 cycles.

This is not a complete list of characteristics of expanded clay concrete blocks. Such forms are readily used for the construction of not only residential buildings, but also garages, agricultural buildings, utility rooms.

Implementation channels

Before drawing up a business plan for the production of expanded clay concrete blocks, you need to decide for whom you will produce them and through what channels to sell the finished product. Most often bought:

construction organizations;
farms;
industrial enterprises;
private persons.

Accordingly, there are two main distribution channels for this product. The first includes intermediaries: shops, wholesale depots, wholesale buyers. To the second - direct sales and customization. To establish these channels allow ads in various media.

In the process of searching for distribution channels, one must take into account the seasonal factor that affects this business. Demand for products appears with the beginning of the construction season - in early spring. It lasts until about the end of autumn, when the cold sets in. But demand for inexpensive construction material always high, so you can find your distribution channels without unnecessary difficulties.

Case registration

You can set up a business as individual entrepreneur, or OOO. When registering, you must specify OKPD 2:

23 Other non-metallic mineral products
23.6 Products of concrete, cement and plaster
23.61 Concrete products of a kind used in construction

Production of expanded clay concrete blocks

As with any production of building materials, the production technology of expanded clay concrete blocks has its own stages. Two main stages can be distinguished.

Own production

To prepare the mixture, the vibrocompression method is used. At the same time, it is extremely important to accurately introduce all components in accordance with GOSTs or TUs developed at the enterprise and approved by the competent authorities. As already mentioned, cement, water, expanded clay and sand are used to prepare the mortar, sometimes glue is added, which gives the surface a smoother look. Cement is taken only grades M400 or M500.

The production technology goes through the following stages:

Preparation of a mixture - mixing the components in certain proportions.
Molding - the mixture is poured into special molds to give products desired shape and sizes.
Hardening - forms are placed on a vibropress, hardening chambers.
Drying - takes at least a day.
Warehousing for storage and transportation on special pallets.

The entire production cycle takes at least seven days.

Production room

To organize production, a search for a suitable premises must be included in the business plan. It must have an area of at least 70 square meters. m., if you assemble the production line yourself, and not buy ready-made. The final size of the area is determined based on which installations are used for production. Good ventilation and heating should be installed in the room itself, the floors should be even.

Separately, it is necessary to allocate a place for drying the blocks. It can be indoors or outdoors. In the latter case, it is necessary to provide a canopy.

Equipment

The main equipment for the production of expanded clay blocks includes:

concrete mixer;
vibropress;
vibrating table;
molding trays.

A concrete mixer costs about 100 thousand rubles. And if there are usually no problems with the choice of a concrete mixer, then there are several types of vibropresses.

For a long-term and large-scale business, it is better to take a high-performance unit that produces from 800 pieces of blocks per shift. It can be operated by two people. Such a machine for the production of expanded clay blocks weighs from 600 kg and occupies an area measuring 2.5 by 1.8 m. As a rule, such an installation allows you to work not only with expanded clay, so you can include the production of other products in the business plan. Such machines can use both removable and non-removable block molds.

If you plan to produce medium volumes, it would be wiser to purchase a ready-made production line. It produces about 12 cubic meters of product per shift and will require 100 square meters. m. of production space. Please note that in order to install it, the ceiling height in the room must be at least 5.5 m. One worker is enough to work on it, and for the acquisition it is necessary to include in the business plan an amount of at least 1.4 million rubles.

Significantly reduce the cost plan will help self assembly lines. You can purchase and assemble the necessary installations for only 300 thousand rubles. It will take about three people to service them.

When choosing a form for machine tools, it is advisable to purchase a detachable one with a locking connection. Then the blocks can be removed carefully without damaging the surface.

Production financial plan

One of the key components of the business plan is the financial plan of the enterprise. To start production, you will need investments for the following items of expenditure:

№	Name of the item of expenditure	Investments (thousand rubles)
1.	Registration and organizational costs	50
2.	Equipment:
	concrete mixer	from 100
	vibrocompression plant	from 60
	vibrating table	from 30
	forms	from 3.5 pcs.
3.	Raw material costs	100 000
4.	Salary for three workers, including deductions	80
5.	Fare	40
6.	Premises for rent	50
7.	Organizational and other expenses	35

With an eight-hour working day and 22 shifts per month, almost 15 thousand pieces of products can be manufactured per month. The price of one block is about 36 rubles. at a real cost of 18 rubles. Profit per month can be about 100 thousand rubles. Given that investments in the business will amount to about 600 thousand rubles, its profitability is quite high. The payback period cannot be called exactly, since it is influenced by many factors. But experts on average call a period of seven to eight months.

It is a lightweight building material used for building walls. Despite the relatively small mass, the blocks are considered durable. The surface of the material does not harm environment, and the manufacture of expanded clay concrete blocks can be organized at home. The technological process can significantly reduce financial costs. The quality of the material will be excellent if good raw materials are used for the production of expanded clay concrete blocks.

Production influences the structure block elements, which can be monolithic or have voids.

The production of expanded clay blocks consists of five stages:

all components are connected;
the prepared solution is poured into molds;
there is a process of solidification and hardening;
blocks are dried for two or more days;
finished material is stored.

The density depends on the ratio in which the raw materials are mixed.

It happens that the resulting mass is dryish. In this case, it is recommended to replace the water with a special mixture, for example, “sand concrete”.

To give the material hardness, a vibropress is used.

For those who decide to start manufacturing expanded clay blocks on their own, it is recommended to take into account an important point - washing powder is used in the production process. It is enough to dissolve one spoon of this agent in water so that the finished material receives a certain level of plasticity.

Also note that the solution should become similar to plasticine before it hardens. To achieve this, it is necessary to mix the dry components, to which water containing the powder is then added.

IN self-manufacturing building material, one should adhere to the technology for the production of expanded clay concrete blocks, strictly observe the proportions of the feedstock. Preparing a plastic mixture is only part of the success. Forming is also important.

It is performed using L-shaped halves of a board up to 2 cm thick. The process affects the dimensions of the blocks - 39 x 19 x 14 cm and 19 x 19 x 14 cm. The weight of one block reaches sixteen kilograms.

In the manufacture of a solution for expanded clay concrete blocks, high-quality components are used. Even strips of steel that act as latches, engine oil that lubricates the formwork, boards on a pallet - everything affects the final quality of the material. The mixture must not contain debris, sand, silt, etc.

The hardening process is of great importance. It is the longest in time, while it is necessary to ensure the immobility of the blocks and normal temperature regime so that the material does not dry out.

The composition of the blocks, their main properties

The main component for filling is expanded clay. It differs by factions, directly affecting the final result. In addition, cement mass, sifted sand, water, additives that improve the quality of the mortar and future block material are used as raw materials. For filling, pumice or slag gravel, crushed stone and algoporite can also be used.

Expanded clay will give the blocks lightness, reduce the degree of thermal conductivity, the cement composition will add strength.

To understand whether expanded clay concrete blocks from the manufacturer are suitable for the construction of your facility, you need to study the characteristics of the material, which include:

Proportions

High-quality raw materials are considered a guarantee of obtaining a good product.

Expanded clay represents granules which receive in the course of firing of clay of easy melting. Particles at breaks are similar to a frozen foam mass. Due to the density of the baked shell, expanded clay receives a good margin of safety. Granules in diameter range from 4 to 8 mm, differ irregular shapes and rounded edges. If a finer fraction is used for manufacturing, then expanded clay sand is measured two times less than granular material.

Cement must be perfectly clean and fresh. It is better to give preference to M 400 and M 500.

With the help of additives, the surface of the granules is obtained with a characteristic gloss. Added to the raw material adhesive composition for stone or tile.

Plasticizers achieve an increase in moisture resistance and resistance to frost. They prevent cracking. Quite often, to reduce the mass of products, manufacturers of expanded clay concrete blocks add wood resin.

The proportions of the original components will be determined by what properties of the material you want to get at the output. Knowing these data, you can calculate the cost of one block.

Approximate amount of raw materials:

expanded clay - 60%;
building sand - 20 - 22%;
cement material - 10%;
clean water - 8 - 10%.

The sequence of loading materials into the concrete mixer is as follows:

water:
expanded clay material;
cement composition;
sand.

Everything is mixed within two minutes, resulting in a strong concrete mass, characterized by low weight and good thermal insulation capabilities.

To give strength, the proportion of cement is increased, but in this case, the thermal conductivity of the material will increase, and the walls will turn out to be colder.

In a simplified version, the composition of expanded clay concrete material is a mixture of a fraction of cement, two parts of sand and three parts of expanded clay.

But there is also non-standard option, in which two parts of sand are used for one cement part, one part of water is used and from 1 to 6 parts of expanded clay stone are added.

The production of blocks is possible on their own, and in this case, differences will also appear in the feedstock:

expanded clay gravel - 8 parts;
sifted sand - 2 parts;
water - at the rate of 225 liters for each cube of the prepared mixture.

In addition, the business plan must take into account that a little more sand will be needed, since three parts are used to form the texture of the blocks.

Used equipment

For the factory production of blocks, several types of lines can be purchased:

To make blocks on your own, it is enough to have a concrete mixer, a vibropress and molds for the material.

Some purchase a small installation capable of producing up to twenty-five cubic meters of blocks in one day. It all depends on the model and power of the device.

If you need to save cash then make homemade equipment. This will require certain details and detailed instructions on the performance of work, which you can find on the Internet.

Manufacturing process

To make one hollow block, you need 0.01 cubic meter solution mass. The weight of the wet product will be 11 kg, after drying - 9.5 kg.

The prepared mixture is filled in special forms. To ensure reliable hardening, a vibrating machine is used. With the help of such equipment, the containers are shaken, from which the mortar mass is distributed and compacted evenly. Upon completion of the vibration with a steel plate, the excess solution should be removed.

Drying in molds is carried out for two days under natural conditions or in special autoclave chambers. If plasticizer components are added to the expanded clay concrete mortar, drying is reduced to six to eight hours. Then the blocks are removed and placed outdoors for one to one and a half weeks.

The finished material remains to be stored in piles and placed in a dry and ventilated room.

Block material classification

By purpose, the blocks are divided into several groups:

wall - used for the construction of walls;
partition wall - partitions are erected from such material;
ventilation - the blocks have special holes into which communication lines are passed;

foundation - differ in strength and density. The group is represented by large-format products, the blocks are corpulent and hollow;
for prefabricated monolithic ceilings.

Conclusion

The technological process of manufacturing expanded clay concrete block material is not difficult, it can be easily organized at home. The material, made in compliance with the technologies and properly laid in the masonry, will give the structure a long operational period, practicality and strength.

Expanded clay concrete blocks are a lightweight building material with high strength, practicality and, most importantly, do-it-yourself performance. Despite the small mass, the modules have an increased density, low thermal conductivity, a variety of model range. The environmental friendliness of the material is another plus of the modules, therefore, if the developer wants to take the construction of the building into his own hands from the very beginning of the process, it is worth setting up the production of expanded clay concrete blocks at his site. Moreover, the manufacture of expanded clay concrete blocks will require small financial investments, and the cost of the module will be significantly lower than buying a finished product from the manufacturer.

Module production equipment

To make expanded clay concrete blocks with your own hands, you need to purchase, rent or make the appropriate equipment, as well as buy high-quality raw materials. And here it’s not worth getting cheap - the more High Quality the source material turns out to be, the more durable and practical the modules will turn out. To facilitate the process and set up a line for the production of expanded clay concrete blocks in the quantity necessary for the developer, the following equipment will be required:

Vibrating table;
Concrete mixer;
Forming metal pallets.

If finances allow, it's a good idea to purchase a vibropressing type installation; it will replace two devices: molds and a vibrating table. It is also necessary to choose a good room with a flat floor and determine a place for drying the modules.

Important! Vibrating tables vary in brand and performance: some of them produce up to 120 modules per hour, and some up to 70 units. For private use, small-format machines with a power of up to 0.6 kW and a capacity of up to 20 blocks / hour are quite suitable. Price gradation within $ 30 - these are ideal devices for their compact size, used for the production of expanded clay concrete blocks with their own hands in private housing construction.

It is also possible to manufacture a machine for the production of expanded clay concrete blocks on your own

It is also possible to manufacture a machine for the production of expanded clay concrete blocks on your own. With a little skill and little skills, the device will turn out no worse than the factory one, but its price will be 10 times lower. We offer a variant of the simplest equipment for the production of expanded clay concrete blocks of the "layer" type - this is a unit equipped with a molding box without a bottom, a vibrator located on the side wall and handles for dismantling the matrix.

Important! The standard dimensions of one block are 390 * 190 * 188 mm, the permissible percentage of voidness is not more than 30%, and the slots can be both round and oblong - it is only important that the void former be made in the shape of a cone, to facilitate the removal of the mold box from finished block.

For the manufacture of the matrix, a sheet of metal with a thickness of 3-5 mm is required, from which a blank must be cut with a margin of 5 cm for the process of compacting the mixture. The molding is made in the form of a through box without a bottom. The weld seam must remain outside, otherwise it will spoil the shape of the module.

For the stability of the machine, strips of shaped thin pipes are welded on the sides of the device, and around the perimeter, equip the structure with rubber upholstery. It is a good idea to equip the entire system with an apron so that the solution does not wake up. But the vibrator is made from the engine of an old washing machine with a power of 150 W (this can be done by shifting the centers). A metal bar with a marginal hole is attached to the shaft - an eccentric, the parameters of which are best determined by trial. If you still have questions about how to make a machine for manufacturing modules, watch the video - the answers will be complete and detailed.

Do-it-yourself preparation and production process of claydite-concrete modules

To prepare the mixture and blocks, you need a form with a smooth surface. It is allowed to make blanks both from a metal sheet and from boards - in this case, the finished module will turn out to be textured. The process itself includes 4 stages:

Mixing ingredients strictly according to the recipe. In particular, sand makes up 3 parts of the total volume of the mixture, water - 0.8-1 part, like cement, but expanded clay should be taken already 6 parts. It is important not only to follow the recipe technology for the production of expanded clay concrete blocks, but also to mix the components correctly: first, water, expanded clay, then cement and sand are placed in the concrete mixer. When using additional components, they are also loaded into the container of the concrete mixer.
After the process, the molding stage begins. The use of a vibrating machine will speed up the process: the mixture is placed in the mold, where the plate is previously laid, the vibration engine is turned on and excess composition is removed.
Raise the plate with the finished form by means of handles, you will get a full-fledged module, which is sent for drying.
Drying lasts at least 48 hours, while the blanks must be protected from the sun and rain. After drying, the plates are removed from the modules.

This is the fastest process in which the manufacture of expanded clay concrete blocks at home does not cause problems. However, if you need to make claydite-concrete blocks with your own hands more durable and dense, it makes sense to add a steaming process, then the material will gain an increased strength and the time for concrete to gain grade strength will be reduced to 28 days.

Variants of the composition of the mixture are different, but sand, water, cement and expanded clay are the main components. As a supplement, you can add saponified wood resins, which increase the frost-resistant qualities of the material, and technical liginosulfonate, which increases the cohesion of the mixture.

And now a little more about how to make expanded clay concrete blocks yourself:

To prepare the solution, the proportions and ingredients are as follows:

Portland cement M400 or slag portland cement - 1 part;
Expanded clay gravel - 8 parts;
Clean quartz sand- 2 parts and 3 parts for the texture layer;
Clean water - calculation of 225 liters per 1 m3 of the mixture.

Advice! To give plasticity, it's a good idea to add a spoonful of ordinary washing powder or dish soap.

All ingredients are poured into a concrete mixer, and here you should first pour out the dry ingredients, and only then pour in the water. If the proportions are observed, then the mass will be similar in consistency to plasticine.

Advice! The resulting block will weigh approximately 16-17 kg. In this case, the shape of the workpiece is allowed as standard sizes, and arbitrary: 390*190*14, 190*190*140 and others.

The molds are installed on a flat surface, from the inside the walls of the workpiece are liberally lubricated with machine oil, and the base is sprinkled with sand.
Fill the molds with the mixture, compact on a vibrating table or apply for this wooden block. Tamping is carried out until cement milk is formed. After that, the surface is leveled, and the blanks are sent for drying.

Important! Formwork is removed no earlier than a day later! It is important to protect the workpieces from direct sunlight, as uneven drying leads to cracking of the surface of the modules.

As you can see, it is not difficult to buy, make equipment for the production of expanded clay concrete blocks at home and complete all the processes. But the modules made in this way will be no worse than the factory ones.

We calculate the cost

All work requires preliminary calculations, otherwise you should not start the production of expanded clay concrete blocks at home with your own hands. To calculate the cost, you will have to accurately find out the price of the components and understand how much a unit of finished material will cost. In particular, considering the standard module 390*190*140 mm, the solution volume is 14 liters. We subtract the void formers, which, as a rule, are no more than 25-30%, the total is equal to 11 liters of the mixture. Now the calculation of the components:

One piece takes 0.005 cubic meters of sand, which fills 5 liters of the total volume;
Expanded clay requires approximately the same amount as sand;
Cement will need 1.25 kg.

It remains to find out the price of the ingredients, take into account water, other components and calculate the unit cost of the module. According to the most approximate calculations, it will be up to $ 5. As you can see, the price is incredibly low. However, for a complete picture, it is not enough to calculate the costs of equipment, labor costs and time, which any developer must include in the calculations. But even with such a complete scenario, the cost of block modules, from which excellent walls made of expanded clay concrete blocks made by one's own hands, will be obtained, is still lower than from the manufacturing plant. Therefore, if you plan to put your house on the site, watch again the material manufacturing technology, videos from professionals and start planning the process of launching the production of expanded clay concrete blocks on your site - this is profitable, practical and affordable for every craftsman.