Expanded clay concrete blocks are a lightweight building material that is used for laying walls. The products presented on the market, as a rule, are manufactured by one or another plant of expanded clay concrete products (in particular, Aleksinsky). You can also purchase Eurocam products and blocks produced at the expanded clay gravel plant (Vinzili). Despite the fact that expanded clay concrete has a relatively small weight, it has sufficient strength. In addition, the expanded clay concrete surface does not harm environment, and you can make such a block at home. The production technology of products can significantly reduce financial costs. The quality will be high if they are used in their production good materials.

Manufacturing technology

During the construction of low-rise buildings, specialists often erect walls from expanded clay concrete blocks. The use of these building materials promises greater benefits than the purchase of bricks, since the blocks have several advantages. First of all, the laying of expanded clay blocks will require less time and less cement mixture. In addition, the thermal conductivity of the blocks is considered low, due to which the products have high thermal insulation. At the same time, the production of expanded clay concrete blocks is a simple process. The technology for creating expanded clay concrete mix by Eurocam is similar to the methods for manufacturing similar building materials. If there is such a need, then you can make a solution with your own hands or purchase materials made at the factories of Aleksin or expanded clay gravel (Vinzili). The plant of expanded clay products produces high-quality products. To do this, you only need to observe the technology and the proportions of the components. Before starting work, it is important to know in advance about the advantages and disadvantages of expanded clay concrete. The process is divided into several stages:

Laying

It is impossible to fill holes inside expanded clay blocks with a mixture - the blocks will lose their insulating characteristics.

Since the first line of masonry is the foundation of the building, the blocks must be distributed especially carefully and accurately. After laying every two or three expanded clay blocks, you need to check how even the masonry is. To do this, you need a building level. Then fill in the gaps cement mortar. Each subsequent layer is laid in the same way. It is also important to remember that the seams should not stand out too much. However, it is necessary that they securely hold the remaining blocks. So, the width of the seams can be about one and a half centimeters.

Experts note that it is impossible to fill the holes inside the expanded clay blocks with a mixture. First, you spend on it a large number of cement, and secondly, the blocks will lose their insulating characteristics. In addition, it is worth taking into account how you will finish the wall. For example, if you plan to clad claydite blocks with bricks, you can not deal with additional wall decoration. And if you do not intend to veneer the surfaces, then do the "joint".

* Calculations use average data for Russia

Expanded clay blocks are lightweight blocks for laying out walls. standard sizes 190x190x390 mm. This material, like the more familiar and common cinder blocks, is made by volumetric vibrocompression. The only difference is in the raw materials - for the manufacture of expanded clay concrete blocks, a special mixture is used, which ideally should consist of expanded clay itself, sand (expanded clay, enriched or quartz) and cement.

Expanded clay blocks are one of the most environmentally friendly types of building materials comparable to ceramic bricks, because only natural materials are used in their production. natural materials. True, there is one condition here: raw materials for the manufacture of expanded clay concrete blocks must be mined only in clean deposits and not contain radionuclides. Poor-quality raw materials can release radon, which is heavier than air and poses a risk to human health. Therefore, it is necessary to be very careful when choosing a supplier of raw materials for the production of expanded clay blocks and be sure to measure radiation doses upon receipt of a new batch.

Expanded clay blocks are distinguished by a wide variety of textures and shapes, which makes it possible to use them even to create complex architectural structures. They are well combined with any kind of small building materials, metal structures and reinforced concrete products. Their additional advantage lies in the absence of the need for additional finishing of the facades of structures built from this material. The use of such material allows to reduce the weight of the structure up to 35-40%. Among the main characteristics of expanded clay blocks can also be called relative frost resistance and strength, lack of shrinkage, which avoids the occurrence of cracks on the walls and changes in the geometry of the walls over time. Due to the long cooling time of the material, temperature fluctuations inside the building are reduced. The cost of construction using expanded clay blocks is at least 30% lower than the cost of projects using bricks.

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There are, of course, disadvantages of this type of building materials. Expanded clay blocks are more fragile than bricks. They have a porous structure, as a result of which their strength and frost resistance may decrease slightly (depending on the number of freeze-thaw cycles for outdoors). However, the use of expanded clay concrete blocks remains one of the most profitable options for the construction of low buildings. Now some developers use them even for the construction of frameless multi-storey buildings. They are also used as ceilings over unheated spaces, for bridge carriageways, power line pylons, structures in mines, in agricultural construction, and even for the construction of some types of inland vessels.

In size, expanded clay concrete blocks are slightly larger than one and a half bricks. On the one hand, this slightly limits the scope of their application, and on the other hand, due to their small size, it is convenient and profitable to transport and store them. In addition, their installation does not require additional expensive fixtures and equipment.

Thus, we can conclude that the production of expanded clay concrete blocks is a profitable and promising direction for starting your own business. In addition, competition in this segment, in contrast to the building materials market, in general, is not yet so great. The fact is that expanded clay blocks are not yet so popular in our country, and this must be taken into account when organizing their production. Abroad, the share of construction from expanded clay materials exceeds forty percent. Moreover, they are most widely used in European countries, where this building material is called bioblocks. In Russia, this indicator fluctuates, according to various sources, in the range from five to twelve percent.

What expanded clay blocks are most profitable to produce? Despite its rather wide application, in our country this building material is still used mainly for the construction of walls. For these purposes, expanded clay concrete blocks of grades 300, 400 and 500 are used.

The production of expanded clay concrete blocks does not require large investments, and the technology for their manufacture is quite simple. However, there is a shortage of quality products on the market, which is associated with the desire of small producers to minimize their cost and increase their profits. There are also several large factories where expanded clay blocks of higher quality are produced (but their cost, especially with delivery, turns out to be considerable). Therefore, if you can provide a sufficiently high quality of your building materials at competitive prices, then you can count on high demand for your products and good profits.

Ready-made ideas for your business

As mentioned above, the following raw materials are used for the production of expanded clay blocks: expanded clay, sand, cement, and also water. Most often, in order to save money, manufacturers prefer expanded clay sand (river sand or, worse, quarry sand), but to increase the strength of the finished material, experts advise using quartz or enriched sand. In this case, the finished blocks can even withstand reinforced concrete floor slabs. Also, in order to save money, some manufacturers reduce the content of expanded clay and cement in the mixture, as a result of which such blocks have poorer thermal conductivity and lower strength. Although the molded block hardens in a day, but for full readiness it is necessary to withstand another seven days. There are recommendations in order to speed up the production process to dry the molded blocks using auxiliary equipment- heat guns. But this is unacceptable according to the production technology, since with such accelerated drying, the blocks become brittle and quickly crumble.

The cost of cement (grade M400D20 or M500D0) will be 200-220 rubles per bag (the final cost depends on the size of the lot), expanded clay - 950 rubles per 1 cubic meter. meter, sand - 2500 rubles for 13 tons.

The production process of expanded clay blocks is quite simple and consists of several main stages. At the first stage, from all the components - expanded clay, sand, cement and water - a mixture is made for molding blocks. The ratio of components is determined according to GOST and TU. The given proportions must be maintained as accurately as possible, as they determine the quality of the finished product. On the next step molding is carried out - the mixture is poured into special molds. After that, the molds with the mixture are placed on a vibropress, and then left to dry. Finished blocks are stacked on pallets and sent to the warehouse.

Ready-made ideas for your business

For the production of expanded clay blocks, special equipment is required, the main of which is a vibrocompression unit and a concrete mixer. The choice of vibrating machines in the domestic market is very large. You can find a model of any performance and in the widest price range. If you consider your business as a long-term one, then it is better to give preference to a high-performance brick making machine, which allows you to produce from 800 units of products in an eight-hour work shift. Two people are enough to work with such equipment. The dimensions of such a model are approximately 2.5 by 1.8 meters, and the weight is less than 600 kg. An additional advantage of such an installation is that, in addition to expanded clay blocks, it can also produce products from slag, concrete, etc.

In addition to a concrete mixer (about 100 thousand rubles), a vibropressing plant (from 60 thousand rubles) and a vibrating table (from 30 thousand rubles, depending on the model), you will also need molding pallets (their cost is from 3.5 thousand rubles apiece). For medium production, it is better to immediately purchase a line that is equipped with everything necessary equipment. Its performance reaches 12 cubic meters. meters of products in one eight-hour shift. To accommodate such a line, an area of ​​​​at least 100 square meters is required. meters. In addition to the area, there are also requirements for the height of the ceilings - they must be at least 5.5 meters, and preferably 6 meters. One worker can cope with the maintenance of such a line. Its cost is from 1.4 million rubles.

Production of expanded clay concrete blocks: the relevance of the business idea implementation + technical specifications material + 15 advantages + scope and types + necessary equipment + product generation methodology + advertising and marketing methods + investment + detailed calculation of benefits.

Such a sector of the economy as construction is developing rapidly. Even despite the crisis, the scale construction works do not decrease. The growth of the market of finishing and building materials gives many start-up entrepreneurs prospects.

For example, the production of expanded clay concrete blocks is one of the profitable areas of the construction business. Opening a business for the manufacture and sale of expanded clay concrete is not difficult, the technology is simple, the cost of equipment is reasonable.

So why not engage in such a profitable activity?

The feasibility of launching the production of expanded clay concrete blocks

The popularity of the construction of various elevated buildings (civil, private, agricultural, residential) is only gaining momentum. And in this process the most common material was brick.

Due to its versatility, it has been used and is used to this day in the construction of many buildings. But the brick has a significant drawback - the high cost. Therefore, it rightly began to be replaced by expanded clay concrete, which is not only cheaper, but also not inferior in quality and practicality.

According to experts, expanded clay concrete lightweight blocks even surpass bricks in their characteristics. This generates demand for the product. This means that their production is a relevant and cost-effective activity. At the same time, few enterprises can compete.

The production of expanded clay concrete blocks for sale can be arranged at home or in auxiliary workshops. However, in the second case, claydite-concrete blocks will be of better quality than “homemade” ones, since their production will be carried out exclusively in accordance with GOST, and technological process controlled by experts.

It is also attractive that the technical equipment for starting production is available, capital investments are justified and quickly pay off. Of course, in winter time expanded clay concrete is not so in demand, but this does not interfere with its production all year round.

Technical parameters of expanded clay concrete blocks and where are they used?

Expanded clay concrete blocks (expanded concrete, expanded clay products) is a building material that is created due to the diffusion of expanded clay granules, cement, sand, water and other additives with air-entraining properties, for example, saponified wood resin.

Also, plasticizers are used as additives so that expanded clay concrete acquires plasticity and elasticity during processing, increased frost resistance and fire resistance.

The production of expanded clay concrete building blocks is necessary:

• construction companies;
• individuals;
• wholesale building bases;
• shops;
• industrial enterprises;
• and etc.

This material is used for the construction of external and internal walls of residential low-rise buildings and their lining, soundproof partitions. Expanded clay blocks are often used to organize a ventilation system. various structures, lay electrical wiring and other communications.

Expanded clay concrete is in great demand in the construction of cottages, fences, pillars, as a foundation wooden houses. It also finds its application in the construction of utility rooms, agricultural structures, garages, in the formation of elements of architectural and decorative purposes.

Expanded clay concrete building blocks will serve as a replacement for curbstones, support for garden and park benches. Monolithic expanded clay concrete is indispensable in the construction of chimneys, stoves, fireplaces. The material has a number of significant advantages and may well be stacked manually without lifting and transport vehicles.

1. Which expanded clay concrete blocks can be produced?

Expanded clay blocks have their own classification. And if you are going to organize their production, you need to understand the types of material that you will sell in the future.

So, your assortment can be expanded clay concrete blocks:

• structural;
• heat-insulating;
• mixed type (structural and heat-insulating).

Each of the above blocks is obtained depending on the composition of the raw material.

If you are in production structural expanded clay concrete blocks, cement should predominate in the recipe. This material is characterized by a stronger and more rigid structure.

Open production heat-insulating expanded clay concrete blocks makes sense when products are designed for interior decoration residential / non-residential premises. Heat-insulating expanded clay concrete is used for better insulation buildings.

mixed type can be achieved with a proportion of 60% expanded clay, 12% cement, 30% sand, 8% water. Such expanded clay building blocks are also made in order to preserve heat in the room.

Also distinguished:

• partition blocks up to 15 cm wide, which delimit apartments, separate rooms;
• wall - their width exceeds 15 cm, with their help they build external / internal load-bearing walls;
• finishing - produced in a variety of color variations. Their purpose is to give the facade an aesthetic appearance and the arrangement of fences.

Expanded clay concrete is also classified by grade, i.e. depending on the size of the blocks. The production of grade material: 300 (19*19*39 cm), 400 (18.8*19*390 cm), 500 (20*20*40 cm) is the most profitable.

If we talk about mass, then the weight of a standard expanded clay concrete block of grade 400 varies between 10-23 kg. The mass of expanded clay concrete will be affected by its density, which in turn depends on the type (slotted or monolithic).

A monolithic (solid) block has an average ρ = 1000 kg/m3, so it is more durable and weighty. Slotted blocks, characterized by a porous structure, are more vulnerable to deformations. They can have no more than 10 holes. Slotted expanded clay concrete blocks are most often offered in areas where winters are cold.

If you produce a wide range of products, in the near future you can expect a large flow of customers, each of whom will find what he needs from you. Thus, expenses are quickly offset by income.

When production is established, you can think about creating expanded clay concrete for decorative purposes. Cooperating with landscape companies, you will be able to conquer new markets.

2. Method for manufacturing blocks from expanded clay concrete.

In the production of expanded clay concrete building blocks, the main thing is to follow a certain sequence, loading all the components included in the recipe.

First of all, dry cement is placed in the concrete mixer, then sand follows. After thorough mixing, water can be added. At the end of re-kneading, expanded clay is poured into the resulting mass. Its number is determined by the purpose of the blocks.

Care must be taken to ensure that the substance retains moisture. For this reason, sometimes there is not enough water, and it has to be added again in small portions until the claydite filler is covered with a “cement glaze”.

The resulting mixture is evenly poured into molds, sent to the drying chamber and left alone. Expanded clay blocks should set in 24-48 hours. If you hold expanded clay for about 7 days on fresh air, this will give it strength, it will be possible to talk about its complete readiness and the possibility of warehousing.

In fact, special equipment purchased for the production of expanded clay concrete will do everything for you.

All you need is the right combination of all the components and following three steps:

1. Preparation of raw materials (dosage, mixing).
2. Formation of expanded clay concrete blocks (unfolding in forms).
3. Drying.

Equipment for the production of expanded clay concrete blocks: how to equip the workshop?

The implementation of the idea of ​​the production of expanded clay concrete is possible only with certain equipment. First of all, this is a set of a concrete mixer (concrete mixer), due to which all components are mixed, and a vibrating machine.

concrete mixers are large containers that are attached to a rotating axis. On their basis, different parts of the mixture become a homogeneous mass. Concrete mixers can vary in tank volume and rotational speed (the number of revolutions per unit of time).

If you give preference to concrete mixers with a large displacement, free yourself or workers from the frequent laying of the components of expanded clay concrete building blocks, which means you will save time and reduce labor costs.

In one shift, a good concrete mixer and vibrating machine are capable of producing about 200 products of standard sizes. If you have a good budget, buy automated equipment for the production of expanded clay concrete blocks.

The manual version will be cheaper. When purchasing mechanisms, take into account:

• volumes that you plan to sell;
• the type of product itself;
• investment;
• conditions offered by the equipment manufacturer (is it provided service maintenance whether there is a possibility of commissioning by specialists).

For vibrating machines manual type is characterized by small size, so they are purchased for the production of expanded clay concrete blocks at home. The main elements of the apparatus are the body and the vibrator. The last detail is responsible for the product of vibrations that contribute to the uniform pouring of the solution into molds.

Even in vibrating machines there are removable void formers. Their presence makes it possible to produce both monolithic and slotted blocks. Manufacturers offer many models, many of which are made per shift of 1 thousand expanded clay concrete blocks, so they will pay off in a few months. Approximate price - 10 thousand rubles.

Must also be purchased vibropress. It also plays an important role in the production process. This is a large, complex machine used to create blocks.

Its hydraulic line exerts strong pressure on the hydraulic press (several tons). On the ramps there are void formers pressed into the mold. Ready-made claydite-concrete blocks are taken on pallets.

Using a vibropress, there is no need to resort to manual labor at any stage of production, with the exception of transporting the blocks to the drying place. Through automation, productivity will increase significantly, and the quality will be impeccable. The price reaches 1.5-2 million rubles.

You will also need: vibrating table, set of molds into which the resulting mixture will be poured. At first, you can buy 1 set, but with the development of production, this amount will not be enough. Forms must be of high quality.

Without sparing the money for this item of expenditure, you will receive expanded clay concrete products with a long service life. Machines supplied to the market are not very dimensional. Due to their compactness, there is no need to purchase / rent premises with a large area.

Reliable manufacturers of equipment for the manufacture of expanded clay concrete building blocks of all types are:

• Commander;
• Riphean;
• HESS;
• Stroymash;
• QUADR;
• Prorab;
• Prestige etc.

What is better for the production of expanded clay concrete products - ready-made machines or automated lines?

Mechanized machines with a supporting body have the ability to move. They are equipped with a lever that removes molds automatically, which simplifies production. Some manufacturers also include a press to tamp the block mix into their models. Such machines speed up the work, but are more expensive.

Ready-made machines are indispensable when the scale of your production is large. Moreover, some options can be found at an affordable cost and already complete with a mixer. For example, Rifey-04. Its price is about 600 thousand rubles.

As an addition to the machine that produces expanded clay concrete, you can purchase loaders that pour the mixture into molds.

by the most the best option workshop equipment is automated line. It includes: a concrete mixer, a vibropress, molds, an installation platform and other equipment. However, a good car will cost you no less than 1.5 million rubles.

Do not worry if you cannot equip your expanded clay concrete block plant with high-tech machines. You can get by with cheaper equipment, although without an automated line, the costs will go to pay salaries, because. manual labor will increase.

Conditions for launching the production of expanded clay concrete blocks, personnel

In order to organize the production process and produce expanded clay concrete blocks, it is necessary to create favorable conditions. The room that you will rent or buy should be large and have a flat floor.

It is also mandatory to have ventilation system, heating. Naturally, without electricity and running water, the production of expanded clay concrete is impossible. The building should have rooms where expanded clay concrete blocks were dried and stored, rooms where workers would rest and dine.

In addition, you will need:

• security system room, where the operator will monitor the progress of the production process;
• first-aid post (the area is usually 12 m2 or more);
• restroom with bathrooms;
• a room where the staff takes food (in area, preferably, no less than a medical center).

Ideally, you should allocate a place for free parking.

Hiring of personnel occurs depending on what equipment you purchase. If this is an automated line, the number of employees is at least 3. With this approach to production, about 120 pieces can be produced per hour, during an 8-hour working day - 960 pieces. blocks.

When you have an ordinary vibrating machine and a concrete mixer, you will still have to find a job more people. Only 2 people are needed to operate the concrete mixer.

It would not hurt to hire 2-3 people to control the quality of the finished product. Women are more suitable for this position - they are neat, attentive, patient. If you have your own delivery service, you will need couriers and a driver, movers, and a vehicle.

An operator is invited to receive calls and place orders. He must be well versed in technical specifications expanded clay concrete blocks, delve into the production process in order to answer customer questions.

Since the machines are easy to learn, it is not necessary to place high demands on the education of future workers. Medium special is fine.

But with age, things are a little different. It is better to hire young people for the production of expanded clay concrete blocks, because. they get faster and easier to master the technique. Looking for workers with experience will make the process easier and faster as you won't have to worry about training them.

Ways of advertising and marketing of expanded clay concrete blocks

The sale of expanded clay concrete blocks should be oriented to wholesale buyers, developer companies. You need to bet on them, since a larger volume of sales will allow you to quickly recoup the costs.

Potential clients are looking for:

1. Your proposal for the production of claydite concrete blocks to order can be placed in the media, large-circulation print media, on television, radio.

You need to use all sorts of ways to surely interest as many people as possible. So take advantage of the internet. Involve a specialist who would create a corporate website for you.

For any business, including the production of expanded clay concrete blocks, this is a necessary and indispensable attribute. This representation of your enterprise in a virtual environment will be an effective tool that will lead to a response from a wide range of audiences.

2. Do not ignore the standard methods of promotion - posting ads on the appropriate boards (like Avito, etc.)
3. You need to take care of the availability and distribution of booklets, where to display complete catalog the products you are manufacturing. Booklets should also include contact information. The rest is up to you.
4. And also right decision there will be mutually beneficial cooperation with customers when, at your request, they leave positive feedback about the quality of the blocks made by your company on Otzovik, Yandex.Market, and you give them a discount in return.

In the future, hold promotions, slightly reduce the prices for expanded clay concrete blocks in order to have an advantage over competitors and be in demand.

What capital investments are needed when organizing the production of expanded clay concrete blocks?

Many entrepreneurs manage to realize the idea of ​​producing blocks of expanded clay concrete with an investment of 300-400 thousand rubles. But in order to, you need to spend more money.

The cost of renting a room of 300 m2 starts from 150 thousand rubles per month. The arrangement of all rooms (first-aid post, dining room, restroom, etc.) will cost at least 300 thousand rubles. To install cameras for video surveillance of the production process, you will have to pay from 30 thousand rubles.

Now for the equipment for creating expanded clay concrete building blocks. If you take a budget machine, the price will be about 200 thousand rubles. More powerful equipment will cost 1.3-1.5 million. You also have to pay for its commissioning.

Additional items of expenditure will be: registration of a state of emergency and other organizational costs - 50 thousand rubles, the purchase of a raw material base, depending on your plans.

For example, with a standard dosage, for 100 kg of a substance (about 9-10 product units are obtained at the output), you will need:

This means that the production of a large batch will take 100 thousand rubles. Also, keep in mind fare- approximately 40 thousand rubles. , wages (depending on the number of employees, at least 60 thousand rubles), utility costs and deductions for advertising, communications.

If we take these average indicators and add them up, it turns out that at least 1 million rubles must be allocated to start production. When buying expensive equipment, this amount will increase by an order of magnitude higher.

Expanded clay blocks - the best building material?

You can make a conclusion by watching this video:

What profit will the production of expanded clay concrete bring?

In practice, it has been proven that with a competent approach, a properly drawn up business plan, effective marketing, the manufacture of expanded clay concrete products helps to reach a high income. But this happens in parallel with the growth of the clientele. After all, it is obvious that the more blocks they buy from you, the more revenue will be.

When setting the price per unit of production, it is necessary to build on the pricing policy in a particular subject of the Russian Federation, product labeling.

Here are the average prices for expanded clay concrete building blocks in the Moscow region:

Of course, you have the right to set your own price, up to 100 rubles. per piece

Just take into account the cost of the block:

Let's calculate the approximate revenue:

Your monthly profit will be more than 100 thousand rubles, provided that fixed costs do not exceed 160 thousand rubles, and material costs - 261 thousand rubles. In the future, you will be able to expand your production and get more.

Business payback - 1 year.

Production of expanded clay concrete blocks- this is not a gold mine, but a profitable and promising business. Its organization is not accompanied by high investment risks, since the competitive niche is not overcrowded, and the products themselves are in demand everywhere.

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Building a house with your own hands is one of the important goals of a real man's life. If the budget is not limited, you can hire a construction team, and if you want to save money, you will even have to take over the production of the material. Recently, expanded clay concrete blocks are often used in construction, which have high sound and heat insulation properties, and an absolutely environmentally friendly composition.

It’s not difficult to do it yourself, the main thing is to follow the production technology, buy the right amount of components. You will be pleasantly surprised by the result, and save your money.

Manufacturing technology

Cement, sand and water are binding substances, and expanded clay gives the main qualities to the finished material. Cement is needed brand M400 and above, the sand must be clean and fine. Can be added to regular washing powder, it is able to increase the plastic properties of the mixture. At home, you can also use dishwashing detergent or liquid soap to replace surfactants that form air pores, increase the frost and moisture resistance of the material. Concrete is best prepared in a concrete mixer (it can be rented) or by hand when a small amount of building material is required. With the help of a trowel, carefully pour in the dry ingredients first, and then, stirring, add water.

The claydite-concrete mixture should stand for some time, then you need to mix everything thoroughly until a homogeneous mass resembling plasticine.

Preparation of materials and tools

In order to make expanded clay concrete with your own hands, you will need:

• expanded clay;
• cement;
• sand;
• water;
• boards;
• a metal sheet;
• Master OK;
• shovel;
• concrete mixer.

Formwork preparation

Internal walls must be lubricated with used engine oil.

To shape the future product, you will need wooden planks not less than 2 cm thick, thin metal sheet, hacksaw, tape measure, pencil. As for the sizes, they usually choose standard ones, for example, brick or cinder block. Having decided on the size, you can start marking, and then cut out 3 parts from the boards with a hacksaw: a pallet and 2 halves in the form of the letter “G”, then connect everything with metal corners. To make it easier to pull out the blocks, a sheet of metal is nailed to the boards from the inside, and if it is not found, the form is carefully processed from the inside with machine oil. And so that the shape does not change its size, special shutters are made at the ends of the halves.

The choice of the proportion of expanded clay concrete for mortar

• Portland cement M400 - one part.
• Expanded clay - 6-8 parts or 350-500 kg per 1 m3. You can measure in buckets, given that 3-5 kg ​​of expanded clay will fit in such a ten-liter container.
• Sand fraction less than 5 mm - two parts.
• Water - 0.8-1 part; the amount of water per 1m3 for the textured layer must be determined by the consistency on site.
• Washing powder - one part.

molding

It is necessary to cast blocks in a large room with the most even floors. It should not be damp inside, and the recommended air temperature is about 15-18 ° C. Now you need to put the finished formwork for expanded clay concrete blocks on a flat solid metal surface and preferably under a canopy, providing protection from direct sunlight and rain.

Before pouring expanded clay concrete, the walls of the mold should be poured from the inside, and the base should be lightly sprinkled with sand and only then the mixture should be poured. In order to further facilitate the laying of expanded clay blocks, a small amount of expanded clay concrete should be laid. The expanded clay block is usually molded face down and laid out on a pallet.

We seal the solution

Since expanded clay has a large amount air pores, it is lighter than the composition of concrete, and will float to the surface, making the blocks uneven, therefore, at the very beginning of hardening, expanded clay must be rammed into the block. According to GOST, expanded clay blocks must first be subjected to vibration pressing using a special machine, and then dried in an oven. At home, the machine can be replaced with similar movements of a shovel, and then rammed wooden block until "cement milk" appears on the surface. The upper part of the block in the form can be leveled with a trowel.

- a popular material, including cement, sand and expanded clay. simple technology 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 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 performance characteristics 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 an increased level of 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 increasing porosity, soundproofing properties blocks

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 hardwood.

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 engine oil.

1. Make collapsible molds for making blocks.
2. Purchase materials for the preparation of the working mixture.
3. Prepare tools and equipment.
4. Decide on the proportions of expanded clay concrete mortar.
5. Weigh the raw materials and prepare the working mixture.
6. Make product molding.
7. Compact the solution poured into the molds.
8. Dismantle the formwork a day after pouring.
9. 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 sheet steel is used. 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:

1. Transfer the sketch dimensions to the material.
2. Cut formwork blanks.
3. Prepare two L-shaped walls.
4. Connect the workpieces using metal corners.
5. 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 expanded clay concrete mixture with a density of 1.5 t/m3 will require:

• 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. The layout of the finished product should be done in one layer 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 independently master the production of expanded clay concrete blocks by preparing the necessary Construction Materials and carefully studied 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.