Composition of aerated concrete: components and production technology. Aerated Concrete Machine Overview Aerated Concrete Block Machine

• Staff
• Sales
• Taxation system
• Permissions to open

How to organize a mini production of aerated concrete in the current realities, and is it even worth climbing into this niche in the current competition, because a small enterprise will not be able to “survive” at the same prices for its products as the flagships of this niche, and a large one requires huge investments. Let's try to understand this issue.

How to start an aerated concrete business

To organize a business, you will need to rent a room. Its area, of course, depends on the scale of production, and it can vary from 70 sq. m. up to 600 sq. m. m. If the average cost of 1 square. m. per month is about 100 rubles in Russia, then the cost of rent will be from 7 thousand rubles. up to 60 thousand rubles A warehouse for storing aerated concrete is optional, as it is not whimsical and can be stored on the street.

What equipment to choose for the production of aerated concrete

You can purchase equipment for the production of aerated concrete yourself, or you can contact companies that will offer you ready-made lines plus training in production technology. The equipment includes: molds where aerated concrete is poured, an electronic water dispenser, a dispenser unit for bulk materials, a mass cutting device, an activator mixer and a slurry mixer. The performance of various ready-made lines can be different from 10 to 150 cubic meters. m per day. So their cost will be different, about 90 thousand rubles. and higher.

Raw materials used in the production of aerated concrete

One of the main issues in the production of aerated concrete is raw materials and their suppliers. The components in the manufacture are:

• water, in the amount - 250-300 liters per 1 m3 of aerated concrete, temperature 40-60 gr.
• Portland cement, in the amount - 260-320 kg per 1 m3 of aerated concrete.
• fillers, in the amount of 250-350 kg per 1 m3 of aerated concrete, river or quarry sand can be used as it,
• curing accelerator,
• caustic soda
• blowing agent, in the amount of 0.5-0.7 kg per 1 m3 of aerated concrete, it is aluminum powder.
  

Your task is to find profitable suppliers of raw materials in your area.

Manufacturing technology of aerated concrete blocks

The production of aerated concrete blocks includes the following technological algorithm:

1. form preparation,
2. preparation of aerated concrete mortar,
3. array filling,
4. cutting aerated concrete massif,
5. heat treatment,
6. disassembly of the array into separate blocks.

Staff

Not only the area of ​​the required premises and the volume of raw materials, but also the number of jobs depends on the volume of production. With minimal volumes, you can do without hiring workers, the entrepreneur himself can handle it, but if you want to produce on a larger scale, you can’t do without hiring staff (from 2 to 10 workers). You should think about a two-shift work day. As for wages, it is equal to 100-200 rubles per 1 cubic meter. m. of manufactured products. This is somewhere around 20-30 thousand rubles. per month.

Sales

After the production of products, the question of its implementation arises. You can sell finished products to construction companies, private developers, and there are individual customers. It is only necessary to advertise your production: in newspapers, at construction markets, when leaving the city, near cottage settlements under construction, etc.

How much can you earn in the manufacture of aerated concrete blocks

What profit can the production of aerated concrete bring? Let's give brief economic indicators.

The cost of 1 cu. meters of aerated concrete will be about 1500 rubles. It consists of the cost of cement (250 kg - 1000 rubles), sand (300 kg - 180 rubles), aluminum powder and chemical additives (150 rubles), wages and overheads (150 rubles). In Russia, aerated concrete sold for at least 2500 rubles. for 1 cubic meter. Accordingly, your minimum profit will be 1000 rubles. and more. The advantage of this business is that it does not require large working capital, since from the time of purchase of raw materials to sale finished products may take no more than 2-3 days.

How much money do you need to invest to start a business

The cost of creating a production facility for the production of aerated concrete will amount to 30,000-85,000 rubles, depending on the capacity of the produced concrete, (capacity 12 - 50 cubic meters per shift). The cost of molds for the production of blocks is 30,000-40,000 rubles (1 cubic meter of mixture is poured into 1 mold).

• Total: 60,000-125,000 rubles.
• You will also need consumables (per 1 cubic meter)
• Powder aluminum, 500 gr. 105 rub. for 1 kg.
• Sand 300-350 rubles. for 1 cu. meter (1.3 tons).
• Cement 100 kg. 380 rub.

The cost of producing aerated concrete blocks is insignificant: 520 rubles. for 1 cu. m. The profitability of the production of aerated concrete in all regions is high.

Which OKVED to indicate when registering a business for the production of aerated concrete

OKVED 26.61 - production of concrete products for use in construction; OKVED 23.69 - production of other products from plaster, concrete or cement. If you plan to wholesale aerated concrete, then you must specify OKVED 46.73.6 - wholesale of other building materials and products.

What documents are needed to open

It is necessary to register a business entity: most often it is an individual entrepreneur. If it is planned to sell materials through large companies, then it is recommended to register a limited liability company. Prepared documents are submitted to public authorities or to multifunctional public service centers (MFCs). You must also register with pension fund, social and health insurance fund. For settlements with legal entities you need to open a bank account.

Taxation system

To conduct this business, it is better to choose a simplified taxation system, the simplified tax system - “Income minus expenses”, since in the production of blocks there is a constant cost for raw materials. The only requirement in this system of taxation is proof of expenses. The tax will be from 5% to 15%.

Permissions to open

To open the production of aerated concrete, a business license is not required. But you need to get permission from Rospotrebnadzor. To do this, you must provide the following documents:

• constituent and registration documents;
• premises lease agreement;
• copies of documents for equipment.

In addition, it is necessary to obtain permission from the fire department, the sanitary and epidemiological service, and environmentalists. The lease agreement for the premises must be drawn up for a long period.

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

What you need to know about cellular concrete?

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

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

The composition of aerated concrete blocks

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

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

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

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

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

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

What equipment will be needed?

The production technology of aerated concrete is relatively simple. Nevertheless, artisanal methods will not work here. You need to purchase special equipment, which is usually ordered in a complex from the manufacturer or its official representative - this is the most profitable option. This is not just one installation, this is a whole automated mini-factory. Sometimes the manufacturer even provides the services of a specialist who will advise on the installation of such a line, help to set it up and select the optimal composition for the mixture used for such equipment.

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

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

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

1. Stationary lines have a daily capacity of up to 60 cubic meters of finished products. As a rule, they require storage and production facilities with an area of ​​at least 500 m². Main Feature such lines is that the molds drive up to a stationary mixer and are filled with a solution there, after which all other technological stages. This is a very simple technology, in order to service such a line, it is enough to hire one additional worker.
2. Conveyor lines are needed where high productivity is required - up to 75-150 m³ per day. Here, production is carried out at a faster pace (of course, the maturation time of the product does not change, it does not depend on the line). However, conveyor lines require large areas industrial premises, and at least 8 people will be needed to service them, although most of the technological processes here take place automatically.
3. Mini-lines cannot boast of high productivity, up to 15 cubic meters of finished blocks per day. The difference from stationary lines is that the mixer moves in them, and the molds are installed permanently. The main advantage is that they do not need large production areas, 140-160 m² is enough, so they are popular as a starting option.

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

Production stages

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

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

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

The semi-finished product is poured into molds, kept for 4-6 hours, after which gas blocks are cut. Before gaining strength, they should lie down for another 10-18 hours.

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

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

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

Aerated concrete is one of the most popular and cheap materials in the modern construction market. The demand for this material is increasing every year. In this regard, there is a need to expand the volume of its production. Therefore, the production of aerated concrete blocks is a promising business for organizing your own business.

Of course, if you know how to organize a business: the sequence of manufacturing steps, what kind of premises, equipment and raw materials will be needed, as well as the size of the initial investment. We will consider all these issues and other aspects of the aerated concrete business in this article.

Why aerated concrete?

To begin with, we will find out whether it is profitable to make aerated concrete, whether it will be in demand.

This building material is a stone with a porous structure. It belongs to the group of cellular concrete. Due to the porous structure, this material has good thermal insulation data, is lightweight and easy to install. Aerated concrete compares favorably with other materials in a number of qualities. Namely:

1. Has light weight.
2. It retains heat well (which means that you can save a lot on heating and warming the room).
3. It is relatively inexpensive (belongs to the category of the cheapest building materials).
4. Convenient to use (it is easy to transport, mount, cut, etc.).
5. Vapor permeable (during heating, water vapor will go outside).
6. Made from natural materials and completely harmless to health.
7. Fire resistant.
8. Perfectly drilled and planed.

Aerated concrete is widely used in the construction of walls for any type of room, including country houses, cottages, cottages and cellars. By the way, one block of it replaces about 30 bricks. Now blocks are made in the size of 10 * 30 * 60 cm. There are also larger ones - 20 * 30 * 60.

Aerated concrete is divided into 2 types: autoclaved and non-autoclaved. The first type is more durable and has a wider scope. However, its production will require a solid start-up capital. In particular, the production of autoclaved aerated concrete requires more expensive equipment. Its starting price is 2 million rubles.

In general, this material is constantly in high demand on the market. With the right approach, the production of aerated concrete is a very profitable area for business. So we draw up an IP, and proceed to organize our business.

We select a room

For production, you need to find a room. What will be its area depends on the planned production volumes. The production of aerated concrete blocks can be around the clock or work only 1 standard shift - 8 hours.

If aerated concrete will be produced 24 hours a day (in 3 shifts), this will require a spacious workshop with an area of ​​​​approximately 600 square meters. m. For production in 1 shift, a room of 70-80 square meters is sufficient. m.

Equipment: Options, Components and Turnkey Solutions

Equipment for the production of aerated concrete

To open a business, you will need an aerated concrete plant and molds.

Eat different variants equipment:

1. Semi-automatic installations (from 200 thousand rubles).
2. Lines for automated production (2 million rubles or more).

Having bought a semi-automatic installation, you can count on a performance of 2.9 cubic meters. m of aerated concrete for 1 shift. The automated line has a much higher productivity. It can make about 100 cubic meters per shift. m. material. To purchase forms, you need to prepare 18 thousand rubles.

The production line can be assembled from individual parts. In this case, you need to buy separately:

• Dosers (for measuring water and bulk materials).
• Pallets to move molds around.
• The forms themselves.
• Faucets.
• Block cutting machine.

The best option to organize round-the-clock production of gas blocks is a conveyor installation.

The estimated cost of equipment for making non-autoclaved aerated concrete is shown in the table.

Table. The cost of non-autoclave equipment

If your goal is the production of autoclaved gas blocks, you will have to spend more on equipment. At least for the reason that in addition you will need an autoclave installation.

As for the molds for pouring the mixture, they are of 2 types:

1. Collapsible (you can remove the sides and combine the filled mixture).
2. Cap (removed from hardened blocks).

Raw material set

Gas blocks are obtained on the basis of a hardened mixture. The set of components for it is very simple. To make aerated concrete, you will need:

1. Sand.
2. Cement (grades M-400 and M-500 are suitable).
3. Lime.
4. Gasifiers.

These are the main components. It is possible to add additional ones - gypsum, slag, etc.

It is important to find suppliers of raw materials before opening an enterprise. The productivity of production depends on their reliability.

How aerated concrete is made: production technology

To get ready-made building materials at the exit, you need to follow 6 steps:

• Prepare forms.

Most often in the gas block shop they use rectangular shapes. Their preparation consists in warming up. Before pouring the mixture, the molds must be warmed up to +40°C.

• Prepare the mixture.

To do this, mix all the components (sand, cement, lime, additives). Fill them with warm water. A blowing agent is also added to the mixture. To prepare such a composition, you need a mixer. Due to the fact that aluminum powder reacts with lime, a large number of bubbles appear in this mass.

• Pour the mixture into molds.

When the mixture is ready, it must be poured into heated molds. It is important to level it.

• Provide thermal insulation.

In order for the mixture to harden well and form pores, it needs heat. Therefore, after pouring into molds, the mixture is covered on top with a heat-insulating material.

• Cut the hardened mixture into blocks.

After 2 hours, the hardened mass is pulled out of the moulds. Forms are well cleaned from the remnants of the mixture. The finished array is cut into blocks of standard size.

• Perform drying.

Each block must be dried. Drying is carried out in special chambers or in a warm room.

To obtain autoclaved aerated concrete, the blocks are steam-hardened in a chamber. This process takes 12 hours. The non-autoclave type of material is obtained by heating in a natural environment.

How many workers do you need

The number of shop workers depends on the total output

The number of employees that will be required for the production of aerated concrete blocks is directly related to the volume of building material to be made. On average, an aerated concrete shop employs from 2 to 12 people. If you plan a small production in 1 shift, you can do it on your own. Or hire 1 person to help you.

If an automated line is used as the main equipment, it will require significantly fewer people to maintain it than in the case of semi-automated production.

Business promotion, costs and profits

To promote an aerated concrete enterprise, universal methods such as:

• distribution of leaflets;
• distribution of business cards and booklets;
• city ​​announcements;
• PR on the Internet (on free boards, city forums, social networks);
• advertising in print media.

It is important that as much as possible is known about your company construction companies. By establishing partnerships with them, you will have constant sources of orders.

Now let's talk about expenses. Let's calculate the approximate cost of manufacturing 1 cu. m. gas block.

Table. The cost of manufacturing 1 cu. m. aerated concrete

There may be additional costs - for premises, utility services, etc. In each case, their amount is different. But on average, 1 cubic meter of gas block costs no more than 200 rubles.

They sell gas blocks at a minimum price of 2,500 rubles. for 1 cu. m. In a small enterprise, you can make 30 cubic meters. m per day. If, for example, you fulfill the monthly norm for the manufacture and sale of 250 cubic meters. m., you can count on a net income in the region of 180 thousand rubles. Payback of gas-block production is 1-1.5 years.

The modern construction industry is characterized by the combination traditional methods construction with the latest construction technologies. The use of cellular concrete has significantly increased the efficiency of civil engineering and improved the quality construction works. The widespread production of aerated concrete for the needs of private housing construction underlines the increased popularity among developers of budget options. wall materials with sufficiently high strength and thermal insulation properties.

One of such popular building wall materials is aerated concrete used in the construction of low-rise residential buildings and outbuildings. Due to its porous structure, it is cellular concrete and is an artificial porous stone-like formation.

Aerated concrete manufacturers produce aerated concrete products in the form of blocks of various configurations that meet the requirements of the following standards:

• GOST 31359-2007, establishing requirements for cellular concrete intended for the production of wall blocks and panels, slabs, lintels and other building elements;
• GOST 31360-2007, regulating the requirements for wall products made of cellular concrete.

GOST 31359-2007 defines aerated concrete materials as a kind of cellular concrete, which differs from other cellular materials in the way of pore formation (clause 4.2). In terms of its structure, an aerated concrete product resembles a kind of concrete “sponge”, consisting of small bubbles-cells with a diameter of no more than 3 mm.

Due to the finely porous structure, block products, which are capable of producing modern equipment for the production of gas blocks, have physical and mechanical properties that distinguish them favorably from similar products made from other concrete materials:

• low specific weight;
• low thermal conductivity;
• fire resistance;
• resistance to fungi and mold;
• ease of machining;
• manufacturability and application.

Advantages

The following aspects are noted as technical and economic advantages of aerated concrete materials:

1. The weight of building aerated concrete blocks is several times less than the weight of similar products made of brick or concrete. The gas block of standard dimensions 300x250x600 mm weighs only 30 kg, which is more than 3 times less than the weight of the same volume of bricks with dimensions of 60x125x250 mm.
2. The ease of processing products with conventional mechanical tools allows the adjustment of blocks during the construction of buildings to improve the quality of the assembly.
3. High heat and noise insulation qualities of walls made of aerated concrete blocks provide comfortable living in residential buildings.
4. Reliable fire resistance in relation to an open flame ensures the fire safety of the building.
5. The high manufacturability of construction when using gas blocks increases the efficiency and quality of work.
6. The affordable cost of gas blocks provides them with proper competitiveness in the building materials market.
7. The possibility of organizing the manufacture of aerated concrete products as a private business, since the real price of aerated concrete production, a mini-factory or conveyor-type line equipment is relatively affordable. The manufacturability of the production of aerated concrete materials creates the prerequisites for doing business with high profitability.

Aerated concrete manufacturing technology

The initial components used by manufacturers of aerated concrete blocks in the manufacture of cellular aerated concrete material are:

• Portland cement in proportions of 50 - 70% of the volume of the prepared mixture;
• Lime - no more than 5% of the volume of the mixture;
• quartz sand of a fraction not exceeding 2.1 mm, proportions in the mixture - 20-40%;
• water - 0.8-1.0%;
• complex gas-forming additives ranging from 0.04 to 0.09%.

The basic technology for producing aerated concrete consists of several stages:

1. Stage 1 - dosing of the main components - cement, sand, lime - in accordance with the proportions of a given recipe for aerated concrete material.
2. Stage 2 - supply of the main components and water to a special aerated concrete mixer. Thorough mixing of the components until a highly homogeneous mixture is obtained.
3. Stage 3 - addition of a blowing agent to the prepared mixture (most often, the blowing agent is an aqueous suspension of aluminum powder). mixture porousization process. It is important! In progress chemical interaction metallic aluminum, which forms the basis of the powder, with lime and cement mortars free hydrogen is released in the form of gas bubbles, which "swell" the cement paste. Equipment for aerated concrete should provide uniform gas emission over the volume of the mixture in order to obtain a uniform porous structure.
4. hardening gas concrete mix in special forms, cutting blocks of the required configuration. The shape of finished products can be given the most diverse - from traditional parallelepipeds to U-shaped or arched blocks.

Depending on the type of processing of the hardening aerated concrete mass There are two ways to manufacture gas blocks:

• a non-autoclave method, in which the maturation of semi-finished products to a set of regulated strength proceeds naturally without forced exposure to external factors;
• autoclave method or autoclaving, in which the products are subjected to pressure at elevated temperatures in autoclave chambers.

Features of autoclaving aerated concrete block products

If the composition of the equipment that the gas block plant is equipped with includes an autoclave chamber, then the products of autoclave curing are much superior in terms of quality to products made using a non-autoclave method. Shrinkage of autoclave blocks during operation does not exceed 0.5 mm/m, while the same indicator for non-autoclave wall blocks reaches 5 mm/m. The ultimate compressive strength of autoclaved aerated concrete materials reaches 3.2 MPa, for non-autoclaved materials - no more than 1.0 MPa. Autoclaved gas blocks have a stable homogeneous structure, which predetermined their operational properties as a universal building material. Wall buildings with a thickness of 375-400 mm, built from aerated concrete products, have proven themselves well in Russian weather conditions without additional insulation.

The principle of autoclaving cellular building materials is to place already molded products in an autoclave in which the blocks long time will be under the influence of high pressure (up to 1.2 MPa) and undergo steam treatment at a temperature of 190-191 degrees. Z. Such conditions initiate reactions that strengthen the structural density of the material and increase its strength.

Technical equipment of aerated concrete production

To launch production activities for the manufacture of aerated concrete products, a technological line for the production of aerated concrete is completed, which includes the following functional elements:

• dispensers of aerated concrete mixture components;
• aerated concrete mixer (mixer-activator) for the preparation of aerated concrete foam mixture;
• molds for pouring foamed aerated concrete mixture and subsequent hardening;
• devices for cutting gas blocks;
• trolleys for moving finished products to storage.

For work using autoclave technology, the line is equipped with an autoclave chamber and an automatic control and regulation system for autoclave operation modes.

Before organizing a mini-plant for the production of gas blocks or other aerated concrete products, it is necessary to determine the productivity of the production line. The technical equipment of the production site or plant and the degree of automation of regulated technological operations depend on this. For the production of construction products on an industrial scale, completely different equipment will be required than for small-scale production or for the manufacture of gas blocks in artisanal conditions. Production and technological lines for the production of aerated concrete products are divided into three categories.

mini lines

1.mini lines, which are mini-factories with a production capacity of 15-25 cubic meters. m/day of aerated concrete products. They have a low degree of process automation. Actuators are serviced by 2-3 employees. The production areas of mini-factories do not exceed 140-160 sq. meters. The main equipment includes:

• aerated concrete mixer;
• devices for cutting the hardening mixture;
• forms, trays for maturation of gas blocks;
• rail tracks and trolleys for transporting finished products.

In mini-factories, mobile-type mixers are used, which, after mixing the aerated concrete mixture, roll up to stationary stationary forms to fill them with the prepared mixture.

The price of equipment for the production of aerated concrete blocks on such lines can increase significantly when equipped with additional options, for example, an air compressor for better mixing of the concrete mix or automated batchers.

Stationary lines

2. Stationary lines production capacity from 30 to 60 cubic meters. meters/day. An aerated concrete plant of this type is equipped with a stationary aerated concrete mixer, to which mobile carts drive up to fill with foamed aerated concrete mass. The level of production automation is quite high, which allows one or two workers to be involved in the work. The production area of ​​stationary lines does not exceed 500 sq. meters.

Conveyor type lines

3. Conveyor type lines production capacity from 75 to 150 cubic meters. meters/day. Despite the high degree of process control automation, at least 8 service personnel are required to maintain the complex. The area occupied by the conveyor plant for the production of aerated concrete blocks exceeds 600 square meters. meters.

Organizational issues when opening aerated concrete production

The opening of a plant for the production of aerated concrete will require the execution of a number of documents related to the specifics of the manufacture and sale of aerated concrete blocks. If equipment is used for the production of aerated concrete in artisanal household conditions without the use of an autoclave, then no permits for such work will be required. In the decrees of the Government of the Russian Federation dated 13.08.97 No. 1013 and the State Standard of the Russian Federation of 08.10.2001, which determine the lists of products subject to mandatory certification, there are no blocks of cellular concrete and equipment for their manufacture. However, in the case of using autoclave technology, the manufacturer needs to obtain permission from the Gosgortekhnadzor authorities, the operation of the equipment is carried out under high blood pressure. Separately, it is necessary to obtain permission from the fire service, since the electrical power of the autoclave unit is 5-10 kW. The city SES can give its comments, since the use of aluminum powder should provide for the possibility of utilizing the gas-forming suspension based on it.
Not so long ago, only large specialized enterprises with expensive equipment could produce aerated concrete and other cellular concretes.

The introduction of new technical processes has greatly simplified the production of such demanded materials, which gave impetus to the development of the production of aerated concrete products by small and medium-sized businesses.

Equipment for the production of aerated concrete is an industrial complex of units and mechanisms necessary for the manufacture of blocks from autoclaved cellular concrete (better known as aerated concrete), which has become widespread in modern construction, thanks to its irreplaceable useful properties. Light weight, excellent energy-saving and thermal insulation properties, relatively low cost, aerated concrete has gained wide popularity. Compact equipment for its production will help not only save money during construction, but also set up your own small business.

Necessary equipment

More recently, the production of gas blocks required workshops of a large area, and the presence of bulky industrial plants. The development and implementation of new technological processes have greatly simplified the production process and made it possible to manufacture blocks on much smaller units 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 sites, has the opportunity to do this without investing significant funds. Now he can take advantage of several options for developing his own business:

• complete the production line from separately purchased equipment;
• buy a fixed line, for the service of which two people are enough (you can work on your own, attracting a second worker);
• purchase a conveyor line (most of the processes are automated, but a large area will be required, and at least 8 workers for maintenance);
• install a mini-line (the level of automation is low, but only two are needed for production);
• engage in production at a mini-factory (it is not much different from a mini-line, but produces more products);
• buy a mobile installation, which is usually taken in order to provide building material for the construction of your own house.

Mobile plant for the production of aerated concrete blocks

In any case, the purchase of equipment for the production of aerated concrete blocks is a fairly profitable purchase if a person intends to seriously engage in the production of aerated concrete blocks 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, one should sensibly assess one’s own capabilities, the presence or absence of suitable premises, the possibility of hiring workers, or using one’s own family, sources of cheap purchase of auxiliary raw materials, and real ways to sell finished blocks.

What is a set of necessary equipment

Experts recommend that certain precautions be observed when purchasing all components of the working kit separately. All equipment must be purchased from one supplier (it will be cheaper this way), and preferably from one manufacturer.

Otherwise, at the beginning of work on the creation of aerated concrete blocks, certain inconsistencies may be found in the acquired auxiliary mechanisms.

Self-assembly of a mini production kit can be a much less profitable and convenient acquisition, but you should still know what is usually included in a production kit:

• bulk mixer for bulk materials;
• electronic dispenser for measuring the required amount of water;
• block dispenser for bulk materials;
• molds for casting concrete blocks;
• cutting mechanism.

Technical characteristics of stationary equipment, for example, the Inntech-100 Profi line:

• power - 225 kW;
• productivity - up to 51.84 m 3 per day;
• maintenance staff - 10 people.

For a mini-factory, for example, you need:

• mixer-activator;
• water tank;
• complex for cutting blocks;
• pallets and rails for mobile moulds.

If necessary, this kit can be supplemented:

• vibrating sieve;
• steam generator;
• removable caps for steaming molds;
• automatic water dispenser.

The best option for setting up your own production on initial stage can become 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 goes well, there will be low-cost suppliers of raw materials, and small wholesalers who will be interested in selling volumes, and set a low margin at the points of sale, after a while it will be possible to think about expanding.

Necessary raw materials and premises

To establish production, a room with certain components will be required. It should not be in the city center, where rental prices are always high, but also not be far away so that transport costs do not eat up a certain part of the profit.

For any of the existing types of production, there are certain norms for the footage and the number of utility rooms, but it is better to rent an area initially, which implies the possibility of painless expansion at the right time. This is done so that when expanding, you do not have to deal with a tedious relocation, and not lose suppliers and customers 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 plant. The acquisition 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. It will be a simple profit.

According to builder survey statistics, mobile installation saves more than a third of the costs normally spent on the main building material. In addition, construction is going faster, since one block of aerated concrete replaces the laying of 30 bricks.

Mobile installation will help save on construction

An indispensable condition for the rented premises is the availability of electricity and a source of water. And also you will need to take care of the certificate for the products, if it is intended for sale.

The number of required ingredients and the cost of production will depend not only on the integrity of the suppliers, but also on which brand of blocks is planned for release.

To start the production process you will need:

• water (preferably purified from contaminants);
• Portland cement brand 400;
• aluminum powder, which acts as a blowing agent in this production;
• inert fillers;
• curing accelerators;
• plasticizers.

In the general simplified formula, the production of aerated concrete is reduced to the formula water + cement + lime and plus sand.

Profitability and profit

The undoubted benefits received from the acquisition of a mobile installation for building their own home prompted a fairly large number of people to think about starting a similar business on a monthly income scale.

Building materials in the modern environment are in great demand, and the profitability of such production can be increased if you engage in the sale of your own products on your own. In order to decide on such a production, it is enough just to sit down and calculate everything in detail.

The larger the volume of blocks produced, the lower the transport costs and the wholesale price for large purchases. However, it also consumes more 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 idly by, then everything will certainly work out.