Concrete blocks are often used for private and commercial construction. The most popular variety of this artificial stone is aerated concrete, or in other words autoclaved porous concrete. It has unsurpassed energy-saving and heat-insulating properties, is lightweight and easy to process. In addition, you can easily make it yourself.
The technology for manufacturing aerated concrete blocks for individual needs and on an industrial scale will be the topic of today’s article.
Preparatory stage
Materials for production
The use of aerated concrete blocks in construction has many advantages.
Let's list the main ones:
- one 30-kilogram block can replace about 30 bricks at the same time, which affects the construction time of the building;
- the low weight of porous concrete allows the construction of private housing without the use of cranes and other special equipment;
- autoclave gas blocks can be easily processed using ordinary metalworking tools.
The simplicity of the production process makes it possible to produce required amount of this building stone directly on or near the construction site.
All you need is instructions describing the entire process and raw materials:
- water;
- cement;
- lime;
- quartz sand.
Note!
To obtain the porous structure of aerated concrete, a suspension of aluminum powder is used.
This is an active substance that can cause harm to human health.
Remember to use safety equipment.
Devices and mechanisms
Not so long ago, the complexity of technology did not allow the production of various concrete blocks at home, without the use of specialized production lines. Currently, the situation has changed dramatically. There is equipment for: for the production of aerated concrete blocks, for cinder blocks, for bricks and so on.
In the case when aerated concrete is produced not for one’s own needs, but for the purpose of subsequent sale, it makes sense to pay attention to other equipment:
- semi-automatic production lines producing 2-4 cubic meters finished products per day - good for individual entrepreneurship or medium-sized enterprises;
- automatic production complexes that allow the production of up to 100 cubic meters of aerated concrete blocks in 24 hours - suitable for a large enterprise engaged in the production of building materials.
Manufacturing process
Main part of the technological process
The production of aerated concrete blocks begins with mixing the raw materials. Considering that this building material has a porous structure and low weight, a small volume of sand, cement and lime produces enough a large number of ready-made elements.
For ease of presentation, we will divide the further process into several stages:
- Lime, water, cement and quartz sand are poured into a concrete mixer, where they are thoroughly mixed. After 5-10 minutes, a small amount of aluminum powder dissolved in water is added. This substance, having entered into chemical reaction with lime, promotes the release of hydrogen. It is this gas that forms pores in the block ranging in size from 1 to 2 mm, which occupy the entire volume of aerated concrete.
- Immediately after adding the aluminum suspension, the mixture is poured into special molds, where it swells, increasing in volume several times.
- In order for the pores to be evenly distributed and the aerated concrete to harden faster, the forms are placed on a special table or platform, where the future aerated concrete is subjected to prolonged vibration loads.
- On last stage using metal strings from the top edge finished products irregularities are cut off, and the blocks are calibrated to the required size.
Advice!
In order to quickly cut and calibrate aerated concrete, you can use special milling machines.
Autoclave processing
Equipment for the production of aerated concrete blocks also includes autoclave chambers. In them, hardened workpieces are subjected to 12-hour steam treatment at a temperature of 190 degrees Celsius and a pressure of 12 kgf/sq. cm.
After this procedure, aerated concrete acquires greater strength and a uniform structure, and also exhibits minimal shrinkage after completion of construction.
It can be used as:
- heat insulator;
- sound insulator;
- material for load-bearing walls.
By the way, the excellent energy-saving qualities of aerated concrete, which has an excellent thermal conductivity coefficient, allows you to build houses from blocks up to 400 mm thick without using additional materials, retaining heat ( mineral wool, polypropylene foam, polystyrene foam).
Non-autoclave method
When producing aerated concrete, it does not have to be autoclaved. But such material will be less durable and have worse characteristics.
Properties of finished products
The aerated concrete obtained by the method described above has the following properties:
- low density (comparable to the density of solid pine) - it is 5 times less than monolithic concrete and 3 times - for brick;
- compressive strength, which allows the construction of 2 and 3 storey buildings from aerated concrete;
- moisture absorption, which does not exceed 20%, which is comparable to the same brick;
- frost resistance 2 times greater than that of brick;
- high thermal conductivity - 2 times less than that of pine, 15 times less than that of concrete;
- excellent soundproofing properties– with a wall thickness of 300 mm, it completely insulates sound with a power of 60 dB;
- withstands exposure to an open flame at a temperature of 900 degrees Celsius for 4 hours;
- aerated concrete can be easily cut with a regular hacksaw;
- the costs of its purchase or production are lower than those of similar materials.
Conclusion
The video in this article will help you learn more about the production technology of various building materials.
The construction of a house from blocks is progressing faster than from bricks. You can buy them freely, but many make building blocks with your own hands.
Blocks in construction are used not only for building walls. The use of building blocks for the foundation also speeds it up. Of course, these blocks must be very dense: 1.5 tons per 1 cubic m. Making blocks with your own hands, if you look at it, is not such an extremely difficult matter.
Where to begin?
And the beginning of everything is making molds.
Forms
On sale there are molds for building blocks with standard sizes. And at home you can make building blocks in sizes that suit you. We take sheet metal, cut out the required shape from it and weld the shape. Molds are also made from wood; they are good for adobe blocks. There is no need for a bottom here. But the handles on the sides will come in handy, it’s more convenient to work with them.
Material for homemade building blocks
What's great about DIY building blocks is that they use material that you already have or can easily purchase.
Basically, blocks are made from cement with different fillers, but craftsmen, like manufacturers, sometimes do without it. Depending on the selected material, it is possible to produce homemade building blocks of the following types:
- slag concrete;
- blocks based on liquid glass;
- adobe;
- chip concrete or wood concrete.
How the filler is used:
- ash;
- slag;
- dropout;
- crushed stone;
- gypsum;
- perlite;
- expanded clay;
- sawdust;
- straw;
- broken bricks and more.
Blocks without cement
The production of building blocks using this technology is not available to everyone, because the mixture contains liquid glass. Unless you negotiate with the nearest concrete products plant and buy the main component there. The mixture will consist of:
- two dozen parts of river sand;
- one and a half dozen parts of liquid glass;
- 4 parts chalk;
- 3 parts slaked lime;
- 2 parts kaolin.
Manufacturing process
- First the sand is sifted;
- chalk is added;
- everything mixes well;
- slaked lime is introduced;
- kaolin or brick crushed to a powder state;
- liquid glass.
The starting raw material should be homogeneous and dough-like. Before pouring this dough-like mass, wet the inside of the molds. If you wish, you can add color to the building blocks. To do this add:
- chalk of any color;
- red brick ground into powder.
Fillers are added to such blocks: slag, expanded clay, shavings. Their strength is high - they are much stronger than cement ones.
Expanded clay concrete blocks
Expanded clay concrete blocks are one of the types of cinder blocks, where expanded clay serves as a filler.
Compound
- cement - 1 part;
- expanded clay - 5 parts;
- sand - 3 parts;
- water - about one part.
Technology
The technology for manufacturing expanded clay concrete building blocks is generally the same as any other:
- the starting material is placed in pre-lubricated molds;
- compacted;
- the form is removed after 10 minutes;
- the product remains in place;
- after 12 hours it is transferred to a place protected from precipitation and direct sunlight.
- in warm weather the blocks will become hard in a little less than a month.
If you plan to make thick walls (about 0.5 m), then blocks with voids are better. To do this, wooden inserts are inserted into the mold: round or square. And so that they can be easily removed, before inserting, wrap them in roofing iron.
Advantages
- light weight;
- frost resistance;
- breathability;
- moisture resistance;
- strength;
- low cost.
A house made from expanded clay concrete blocks is built faster than from brick; less mortar is needed for masonry.
Adobe blocks
Components
For this type of block, the material is literally under your feet. All you need is:
- clay;
- straw;
- river sand;
- water.
Features of selection
In order for the building blocks to have characteristics that meet all the requirements, you need to know something about the features of selecting components:
- It is better to prepare the clay in the fall, cover it with film and let it overwinter - this will improve its quality.
- First sift the sand, freeing it from impurities.
- Straw can be taken from the field where wheat, rye or barley has just been harvested. If the straw remains from the harvest of the previous year, then the quality will not be the same - after all, after lying there, it begins to rot.
How to determine the percentage of components
- clay - 1 cubic meter m;
- straw - 20 kg;
- sand - 25%.
In order not to spoil the entire batch of blocks, you need to make a small experimental batch. So we do this:
- we combine all the components in small quantities and write down the proportions;
- make a batch;
- form a ball;
- leave in the sun to dry for about 1 hour;
- we throw it on the ground at a height of one and a half meters.
If all components are selected in the required proportions, then the ball will remain intact. Did you add more sand than you should? It will collapse or crack. Is there enough sand? The ball will blur. This is how we practically select the most best option.
Preparation
To prepare the mixture for several dozen blocks at once, you need to make a hole in the ground: round with a diameter of about 2.5 m or rectangular 1.5x2.5 with a depth of half a meter. Line its bottom with polyethylene. Although some ready-made container will do: a trough or old bath. Then everything is done as it was done in the old days: we put on high rubber boots and walk, mixing everything until smooth.
Manufacturing
- While the batch is in the manufacturing stage, we are preparing a platform for the products: we select a flat, sunny place;
- We bring the mixture in buckets;
- fill out forms;
- compact;
- remove excess by running a board along the upper edges of the mold;
- remove the form.
The finished blocks should dry. This usually takes several days. It is important that they are not exposed to rain. Then they are transferred to a shelter and dried further. They will be completely ready in 10 days.
A house made of adobe blocks turns out to be very warm and comfortable. In addition, this building material is environmentally friendly, durable, and fireproof. It is used for buildings no higher than 2 floors.
Sawdust concrete blocks (arobolite)
The technology for making sawdust concrete blocks is similar to making adobe blocks, but the components do not need to be mined, but purchased.
Components
Before you start making, you need to purchase:
- cement - M300 or higher;
- sand - fraction no larger than 1.8 microns;
- not slaked lime;
- sawdust (coniferous wood).
Preparing the Components
- sift through sawdust;
- mix dry cement and sand;
- add lime here and mix again;
- add sawdust and repeat the mixing procedure;
- pour in water;
- In order for the components to adhere well to each other, add calcium chloride or alumina sulfate;
- we control the quality of the mixture.
To control quality, we roll the ball and squeeze it in our palms. If water flows, there is too much of it in the mixture; if the ball crumbles, there is too much sawdust or sand.
Let's start production
- Line the form with plastic wrap;
- add the mixture;
- we ram;
- Without removing from the mold, leave to harden for 5 days;
- remove from the mold and dry further.
The drying process will take a long time - from 1.5 to 3 months: it all depends on the mass of the block.
Equipment
If the construction is large-scale, then it may make sense to spend money on equipment for building blocks. For example: there is a mini-machine for sale for the production of wood concrete RPB-1500 BL. Its productivity is 1 sawdust block with dimensions 19 x 19 x 39 cm per minute. Produced by a Russian manufacturer - INTEK.
Vibrating tables are widely used in the manufacture of building blocks. They solve the problem of compacting mixtures. The vibrating table consists of:
- movable table;
- engine;
- control panels;
- sometimes a transformer is included in the kit.
The compaction of the working mixture occurs under the influence of vibration created by a vibration motor.
Duty cycle
- place the mold on the movable table;
- place half or completely dry mixture into the mold;
- start the engine;
- drying.
How to choose?
There are 3 types of vibrating plates capable of compacting material by weight:
- up to 75 kg;
- from 75 to 160 kg;
- from 160 kg.
Based on these indicators, you should select the optimal vibrating table option for yourself.
Manufacturers
They are produced by:
- Russian company VPK;
- LLC "Stroymash";
- "Red Poppy" plant in Yaroslavl and others.
Vibrating tables are also supplied by foreign manufacturers:
- Spain - Enar and Hervisa;
- Germany - Wacker;
- Italy - Batmatic;
- France - Paclite.
One of the most common materials for the construction of load-bearing walls and partitions residential buildings, as well as small industrial buildings are made of concrete blocks. Their popularity is due to their low cost, excellent performance characteristics and a large number of varieties, which allows you to choose required block for almost any task.
The instructions given in this article will help you learn how to make concrete blocks yourself, and will also introduce you to their existing types.
Concrete blocks for walls
Types of artificial stones made of concrete
Let's look at the main types + characteristics of concrete building blocks, which are most common in modern construction.
cinder block
These wall stones are made using the vibration pressing method concrete mortar on special platforms.
The composition of the mixture from which the cinder block is made may include:
- crushed stone for concrete products;
- brick fight;
- sawdust;
- expanded clay
Specifications Concrete blocks with slag leave much to be desired, but due to the fact that their price is one of the lowest on the market, cinder blocks are widely used in private construction.
But cost is almost the only advantage, since they lag far behind other materials in the following parameters:
- durability;
- heat-saving parameters;
- strength.
The main scope of application of blocks is small buildings, which will not be subject to heavy load:
- sheds;
- garages;
- summer kitchens;
- workshops and so on.
Photo of cinder block
A less common material that is made from the following components:
- organic matter (mainly wood);
- binding element (powder);
- hardener.
Essentially, this artificial stone consists of sawdust encased in a concrete shell.
The advantages of the material are obvious:
- light weight of the concrete block;
- high thermal insulation properties;
- good sound insulation;
- efficient air exchange.
To protect blocks from negative impact environment, the stones are treated with a special solution. This prevents mold from forming and prevents rotting.
Wood concrete is perfect for construction small houses, which are suitable for year-round residence without the use of additional thermal insulation.
Arbolite block
Gas blocks and foam blocks
Cellular concrete blocks, according to GOST, which determines their technical characteristics, must consist of 70-85% artificially created pores (cells) filled with air. The most common are foam and gas blocks.
These materials have the following advantages:
- They are light in weight, as a result of which transportation of concrete blocks and their installation in private construction does not require the use of special equipment;
- easy to process - give the desired shape cellular block You can use an ordinary hacksaw for wood;
- walls made of cellular concrete blocks retain heat well and have excellent sound insulation properties.
Cellular concrete blocks are made from a solution containing sand, cement and aggregate. To form foam, lime, aluminum powder or another foaming agent are added.
Note!
Unlike foam concrete, aerated concrete is subjected to additional processing in an autoclave oven, where it is exposed to high temperature under high pressure (10-12 MPa).
As a result, this material acquires increased strength: it is almost impossible to crumble or break it.
Cellular concrete block
Self-production of blocks
The technology for producing artificial stone from cement mortar with filler is relatively simple, which allows you to make concrete blocks yourself.
Preparatory work
On initial stage the dimensions of the future block should be determined. When self-made parameters of each individual element taken based on the required wall width.
The thickness of the bottom of the block should not be less than 2 cm, and the walls of the voids should not be less than 4 cm. In this case, a standard stone measuring 20x20x40 cm with voids inside weighs about 40 kg, which makes it convenient for laying walls.
For production you will need any flat area covered with plastic film and special molds without a bottom.
The materials for the forms will be:
- boards;
- plywood.
To protect the wood from damage, the inside of the mold is lined with sheet metal. Inserts are made in a similar way, thanks to which voids are formed in the finished block. They improve the thermal insulation properties of the material and make it lighter.
Molds for making concrete blocks
You can produce concrete blocks with your own hands faster if you make several forms in one block at once. To do this, you need plywood or a board with a width equal to the height of the future block. The material is sawn into pieces and fastened with self-tapping screws. Next, internal partitions are made.
Advice!
In order for the frozen block to be easily separated from the mold, all its parts must be lubricated with kerosene, machine oil or antifreeze.
Manufacturing process
For casting blocks from concrete mixture you will need the following materials:
- fine gravel;
- cement;
- sand;
- water;
- lime;
- wire for reinforcement.
The quantity of each component is determined based on your needs for artificial stone. The proportions of cement, sand and gravel are taken in the ratio 1:3:5.
It is better to use a concrete mixer to mix the concrete solution.
For ease of presentation, we will divide the entire subsequent process into several stages.
Self-made concrete block
The technology described above allows, without using special effort, make concrete blocks with your own hands. The technical characteristics of the finished products will be almost in no way inferior to analogues sold in construction supermarkets, and the size will ideally match your needs. In addition, this can significantly reduce the cost of purchasing building materials and their delivery.
The video in this article will help you get acquainted with the material in more detail.
Why make blocks?
What do you need to have for this?
What are the blocks made from?
How to produce them?
Why is it profitable to create blocks yourself?
What is the profit from this?
Where to start and how to develop this business?
In this article you will receive answers to all the questions posed and you will be able to “turn on” for yourself a reliable source of income that depends only on you.
And so, let's figure it out in order.
Why make building blocks?
You have probably noticed that construction has been booming over the last 4-5 years. They build from small and medium-sized private buildings: garages, dachas, estates, workshops, workshops, agricultural buildings, to large industrial and residential buildings, storage facilities, centers. Construction professionals are in demand more than ever before.
New ones appear construction technologies and materials. But are they always available in price and technology to a wide range of developers?
Therefore, they are rarely used in small and medium-sized construction, as in major cities, and in small villages.
Most affordable building material What remains is the so-called cinder block and brick.
Moreover, brick is often inferior to cinder block in price, thermal conductivity and ease of laying.
But hollow-core building blocks are convenient and affordable for most private developers.
Yes, because thanks to its properties:
It is easy to use them to build a low-rise (2-3 floors) structure (garage, house, cottage, outbuilding, workshop, etc.) without even resorting to the services of a mason. (1 block = 3-4 bricks);
Walls made of cinder blocks are sound and heat impermeable;
The price of cinder block is lower than the price of brick, foam block and other building materials due to the low cost and availability of its components (see below);
Only cinder blocks can be made by yourself. You can also make adobe (clay-straw brick) yourself.
So how do you make cinder blocks yourself?
What is needed to produce building blocks?
It is known that cinder blocks were produced by reinforced concrete using special equipment using a steaming chamber. Therefore, the production of a quality block in living conditions was not available.
But if there is demand, then supply is inevitable. And it is!
Since 1994, experience in the production of building blocks in private and small-scale production has provided the answer to the question posed.
What does that require?
Vibrating machine
- Raw materials
- Technology
- Relatively flat area
- Household network at 220V (no comments).
Let's clarify each point in more detail.
Vibrating machine
Eat different designs vibration machines. In domestic production conditions and small businesses, the manual, electric, small-sized cinder block vibrating machine MZ30 (14th year of production) has confidently proven itself in the CIS countries. Popularly known as "The Developer's Dream"
Raw materials
To produce building blocks, the following components are required:
Cement- Portland cement grade 400. Another one is acceptable. But selection of proportions is necessary. For example, when using grade 300 cement, its consumption should be increased by 10-15%.
Fillers for concrete may be the most different materials: sand, crushed stone, slag, granulated slag, ash, sawdust, shavings, screenings, expanded clay, gypsum, brick scrap and other natural and industrial materials.
Depending on local conditions, requirements for the blocks produced and cost, you can select the appropriate filler. I will list several popular concrete compositions and the main groups of concretes
1). Slag from metallurgical plants (gray or dark gray with high cement content, seeded fine fraction) – 9 parts
Cement – 1 part
Water 0.5 volume of cement
2). Granular slag from metallurgical enterprises (yellow-greenish color with a high cement content, sifted fine fraction) – 4 parts
Small screenings – 4 parts
Cement – 1 part
Water 0.5 volume of cement
3). Other cinder concrete
4). Concrete on sand and crushed stone
5). Concrete on brick waste
6). Expanded clay concrete
7). Ash concrete
8). Sawdust concrete
9). Perlite concrete
10). Polystyrene concrete
and other concretes with different combination listed.
Now it is clear that the common name “cinder block” is not the most accurate definition of possible building blocks.
Plasticizing additive- This is not an essential component of concrete. But its presence provides: early strength of blocks (this is very important with limited production areas), improves the quality of blocks (cracking and abrasion of blocks is reduced), water resistance and frost resistance of concrete improves.
The amount of additive is very small - about 5g per block.
Manufacturing technology of building blocks:
- Concrete preparation
- Block production
- Drying and storing finished blocks.
Concrete preparation(using the example of the previously given 2nd concrete recipe)
1). Fill in 4 shovels of fine screenings + 4 shovels of granulated slag
2). Fill up 1 shovel of cement
3). Mix thoroughly
4). Adds dissolved UPD to 7-9 liters of water + 250 ml (half a half-liter jar). The additive solution is prepared as follows: pour 0.5 kg of UPD into a 40-liter container and mix thoroughly until completely dissolved.
5). Stir. In this case, the concrete is qualitatively impregnated with the UPD solution.
Block production
1). Pour ready-made concrete with a small slide into the vibrating machine. Briefly, for 1-2 seconds. turns on the vibrator - the concrete shrinks, with a trowel, in one movement, you level the surface of the slightly settled concrete.
2). Install the clamp and, without much effort, press on it by turning on the vibrator.
Blocks with round and rectangular voids vibrate for 4-5 seconds. until the clamp is lowered onto the stops.
Narrow full blocks (2 pcs.) vibrate for 5-7 seconds.
3). You lift the machine with vibration - the block remains on the platform.
Drying and storing finished blocks
When using UPD ready-made blocks can be removed from the site and stored within 5-6 hours. Without UPD - in two days.
After this time, the blocks do not crumble if the proportions of concrete and the technology for their production are observed.
I recommend storing the finished blocks in pyramidal stacks in one block with a small (2-3 cm) gap between the blocks - for further drying of the side edges.
There are 100 pieces in each such pyramid. Easy to count. It is useful to mark each pyramid with the date and time of production of the last block. This will be useful during implementation. You can ship on the 4th or 5th day.
Production site
- A room with a smooth concrete floor.
Blocks can be produced all year round. Desirable good ventilation and heating in cold weather.
- Open flat area.
It can be concrete or earthen, covered with plastic film to preserve the presentation of the blocks (the back edge does not get dirty).
- An open, relatively flat area without preliminary preparation.
On such a platform you can lay out ready-made blocks on pallets.
Where to start producing building blocks?
1. Select the best local concrete material based on cost and delivery.
2. Calculate the cost of 1 block, taking into account the components of concrete.
3. Decide on the production site.
4. Buy a vibrating machine.
5. Master the given technologies.
At first, concrete can be prepared by hand. Subsequently, it is more effective and easier - on electric concrete mixer volume 0.2-0.5 cubic meters (preferably 0.5, taking into account the future).
Why is it beneficial to create the building blocks yourself?
I will give my real costs for aggregate with delivery and cement, calculation of the cost of producing blocks and the payback of the "Developer's Dream" vibrating machine for the production of cinder blocks in Zaporozhye (Ukraine) in 2004 using the example of concrete made from granulated slag (gray) and cement.
Initial data:
8 cubic meters of slag– 30 dollars/car with delivery within the city (KRAZ or large MAZ)
Cement:
Proportion 1:9 - 0.88 cubic meters or 18 bags of 3 dollars = 54 dollars
Vibration machine price- 200 dollars
Total volume of solution:
Proportion 1:9 – 8 + 0.88 = 8.88 (cubic meters)
Volume of solution per 1 GOST cinder block:
Total volume: 39cm x 19cm x 19cm = 0.014 (cub.m)
volume of voids:
With d = 9.5 cm: 3 x 3.14 x 4.75**2 x 15 = 3188 cc = 0.003188 cu.m
Volume of solution per 1 block at d = 9.5 cm: 0.011 cubic meters
Table of calculation results:
Note:
1. For a cinder block with 2 rectangular voids, less mortar is required (but the strength of such a block is lower)
2. By replacing granulated slag with a local aggregate for concrete that is acceptable to you, the prices of your region (in Russia the retail price of a cinder block is higher) and using the dimensions of a cinder block, you can easily calculate the cost of 1 pc/block and the payback of the machine for yourself.
Calculation of profitability and profit:
|
We accept the initial assumptions: |
||
|
Name |
Range of values |
Reference value |
|
Time to form 1 block (sec.) without UPD | ||
|
Number of blocks per 1 hour, taking into account the loading time of concrete in 30 seconds. (things) | ||
|
Number of blocks in 1 day (8 hours) pieces | ||
|
Retail price of 1 cinder block (in 2005): in Ukraine |
2.0 UAH ($0.4) 15 rub. ($0.5) |
|
|
Profitability(From the previous table it follows that the cost of 1 block is 1/3 of its retail price) |
||
|
Produce blocks per day in the amount of: in Ukraine | ||
|
Produce blocks in the amount of: in Ukraine | ||
|
The cost will be: in Ukraine | ||
|
The profit will be: in Ukraine | ||
Note :
- If you apply UPD, productivity will increase significantly.
- The record belongs to Viktor Romanov and Sergei Rachmaninov, who produced 700 blocks 390*138*188 in a day in July 1998
Business development and expansion
1. Hire responsible employees, worthy of their interest. (In our city - 20 kopecks (0.04 cents) per block, in the region - 0.02 cents.)
2. When starting sales, reduce the retail price, thereby creating worthy competition and receiving grateful customers and their recommendations. (Important! The quality must be worthy).
3. In the warm season or in a heated room (regardless of the season), work can be organized in 2 shifts.
4. In this case, the entrepreneur depends only on: the presence of voltage in the network and the health of 1 work force(at the first stage, before payback, you can work with the machine yourself).
5. If appropriate, rent out the machine to “developers”.
6. Fulfill orders from “developers” directly on their site, saving them money on loading, transporting and unloading blocks.
7. In addition, – you will not need permission from the State Electronadzor, since all equipment is designed for a regular household network!
Decrees of the Government of the Russian Federation dated 08/13/97 No. 1013, Gosstandart of the Russian Federation No. 86 dated 10/08/2001 and Gosstroy of the Russian Federation No. 128 dated 12/24/2001, the list of products requiring mandatory certification does not include building concrete blocks with various fillers (slag, expanded clay , sawdust, etc.), as well as vibration-forming equipment for their production.
Thus, the business for the production of building blocks can be developed in stages:
- Begin with minimum costs for the purchase of a vibrating machine, 1 machine of local raw materials as a concrete filler, 15-20 bags of cement.
Give free advertisements on the sale of high-quality cinder blocks.
Produce 800-1000 blocks. Quickly sell by reducing the retail price.
- Purchase a concrete mixer and the next batch of raw materials + UPD.
Level the price to retail (optional).
Post free ads + paid ones.
- Productively, with accumulated production experience, produce high-quality blocks, managing to fulfill orders.
There is no need to advertise anymore: high quality blocks + word-of-mouth advertising will do the trick.
Organize a 2-shift production of building blocks.
Expand the range of produced blocks.
Purchase additional vibrating machines, and possibly a concrete mixer.
Recruit hard workers
Have time to spend your profits or invest them in new business, just as cost-effective.
What I sincerely wish for you!
Success and Prosperity!!
“Catalogue of complete business packages” masterdela.info
mailto: [email protected],
Ukraine, Zaporozhye, August 2005
Wall blocks have long become one of the most common building materials. When constructing a garage, residential building or other utility buildings for the construction of walls the cheapest building material is cinder blocks. They are made from almost any waste material. At the same time, cinder blocks are laid in walls not only on sand-cement mortar, but also on clay solution, which further reduces the cost of construction. Unlike brick, building blocks are much easier to make at home with your own hands. The process of making cinder blocks and the technology is quite simple and accessible to anyone who wants to save money and who likes to do it themselves.
Briefly, what is a cinder block?
According to the prevailing opinion, cinder blocks are usually understood as blocks made by vibrocompression (vibroforming) from a concrete solution; the main components of the solution are slag and cement as the main binder. However, today cinder blocks conventionally refer to any building blocks obtained by vibrocompression (vibroforming) from concrete mortar. The presence of slag is not necessary - the components of the concrete solution can be: slag, granite screening, granite crushed stone, river crushed stone, gravel, broken brick and concrete, broken hardened cement, broken glass, expanded clay and even sand.
Typically, the size of a cinder block is in the range of 200 mm by 200 mm by 400 mm or less. There are two types of cinder blocks - hollow and solid. There are a great many varieties of blocks: these are ordinary wall blocks(for example, cinder block, smooth block 140), wall blocks (used for the construction of partitions indoors, has a thickness of 90 mm), decorative blocks for walls (decorative block 190), blocks for fences (decorative block 140, decorative corner block), blocks for finishing facades ( façade stone) etc. At home, you can also make bricks from clay - the choice is yours.
To make cinder blocks you need two things: a form and raw materials.
Mold options for cinder blocks
Shape from sheet metal 3 mm thick. Together with your assistants, using a concrete mixer, you can easily “produce” up to 300 blocks per day without much effort. Is it a lot or a little? Judge for yourself: a garage measuring 6x4 m will require 450 of these blocks, and one floor of a house measuring 6.5 x 8 m will require 1000 pieces.
Mold for concrete blocks (all dimensions are internal, welds- outside).
Block making solution prepares like this. Mix the slightly moistened mixture (the amount of water is determined experimentally) in the proportion: cement - 1 part, slag or expanded clay - from 7 to 12 (the proportion is given for M400 cement). Having placed the form on a flat area, fill it with solution and tamp it manual tamper and, aligning along the top edge, cut off the excess with a metal strip. Now carefully remove the mold (it has no bottom) - the block is ready.
Place the form next to it and repeat the process. At the end of the work, do not forget to thoroughly wash the mold with water. After 24 hours, the blocks can already be stored (no more than three in height), freeing up space for the next batch. The size of the form is given in case you plan to lay walls with additional cladding of 1/2 brick. If your building has walls plastered on both sides, then you can take arbitrary dimensions - as long as you can then lift such a block with your hands. And when laying walls 50 cm thick, do not forget to “bandage” every two rows of blocks with a jointed brick row.
Dimensions homemade cinder blocks you can choose "for yourself".
Most simplest form, which satisfied me most, I made as follows. I selected planed boards with a width equal to the height of the cinder block (140 mm). The length of the boards should be no more than 2 m, since working with a longer form is more difficult: you have to make a lot of unnecessary movements. Next you need cross members. The two outer crossbars are connected to the longitudinal boards “on sliding grooves” (Fig.).
Form for three cinder blocks
WITH inside longitudinal boards (between the cross members), every 140 mm, cut transverse grooves with a depth of 7...8 mm using a hacksaw and chisel. The width of the cut depends on the thickness of the separating plates made of sheet iron, textolite, and getinaks. Plates made from other durable materials are also suitable. sheet material, as long as it is smooth enough. From Fig. 1 it is clear how to make a mold. It takes a long time to describe it and there is no point in it, I just want to say one thing: before pouring the solution into it, the finished mold is placed on an absolutely flat surface. It is advisable to paint all mold parts made of wood. oil paint, which will ensure easier removal of cinder blocks from the mold. Each time before pouring the solution into the mold, all its internal surfaces are wiped with diesel oil (diesel oil) or used machine oil. Wipe lightly, not copiously. To reduce solution consumption, and cinder blocks turned out to be light and with voids, - and this is additional heat in indoors, - forms fill the solution up to half, after which champagne bottles are pressed into the solution.
Form filled with solution
If after installing the bottles the level of the solution does not rise enough, the required amount of solution (to the top of the mold) is added with a trowel. After 2...3 hours, the solution will settle significantly and become stronger, then the bottles are pulled out, carefully turning them around their axis, and immediately washed with water, otherwise the solution will stick firmly to them and further use the bottles will be unusable.
The process of removing cinder blocks from the mold is very simple. Just lightly tap the mold around the perimeter with a hammer and disassemble it. The side boards are easy to separate, but removing the divider plates is a little more difficult. You will have to carefully hit the protruding plate from above and slightly to the side with a hammer.
Every day, that is, after 24 hours, I took the almost hardened cinder blocks out of the mold and poured the solution into it again. I did not use any compaction of the solution with a tamper or vibration. A few words about the solution. Despite the fact that it was quite liquid, the cinder blocks, after appropriate exposure, acquired such strength that it was then with great difficulty that they could be split or trimmed.
For one part of “400″ grade cement I took 9 or even 10 parts of slag. There were no defects. Why did I tell you this? Yes, in order to quickly make a significant number of cinder blocks of excellent quality with just a few molds. I made cinder blocks in the evening after work every day, and I will say that this work was not a burden for me. I don’t have a concrete mixer and I mixed the solution by hand in a tray with a capacity of 300 p. Well, if you work together, everything will turn out effortlessly. Alternatively, you can make foam blocks with your own hands .
And another option for making blocks yourself. Sheet iron mold.
I chose the block sizes 510x250x215 mm (volume of 14 bricks). From scrap sheet iron I welded 11 molds without bottoms. I welded 2 handles on the sides.
I spread the roofing material right on the ground and place the form. To prevent the mixture from sticking to the walls of the mold, I wipe them from the inside with a rag moistened with waste oil or diesel fuel. I pour hard expanded clay concrete there. I don't tamp very hard. I remove the first form after filling the 11th - this is about 10-12 minutes. The blocks remain in place for 12 hours. Then I move them under the canopy. They harden at above-zero temperatures for 24 days. I make a canopy from roofing felt, tarpaulin or polyethylene film. Under it, the blocks will be protected from rain and sun.
Tried it make blocks and with voids. He inserted two wooden round timbers, turned into a cone and wrapped roofing iron. Void formers can be round, square, rectangular... Depending on how the blocks are laid, the wall thickness is 215, 250 or 510 mm.
For thick walls it is better to make blocks hollow, for thin walls - filled. Conventionally, walls with a thickness of 215 mm without voids can be called cold, 250 mm - semi-warm, 510 mm with voids - warm.
To make half blocks, I insert a sheet of iron into the mold in the center. In the blanks that are used to form openings in the walls of the house, you have to insert wooden plugs to secure the door and window frames.
Tried it make building blocks, using a vibrator, but the solution goes to the bottom of the mold and the expanded clay does not bind. To prevent this from happening, I welded a common mold for several blocks. The vibrator was attached to the side. I made the walls of the mold higher by 1/3 - this is for concrete shrinkage during vibration.
Fillers can be local materials that are not in short supply: expanded clay, slag, sawdust, etc. To prepare the mixture, I used cement, expanded clay and sand in a ratio of 1:4:1.
The hardest work is preparing the concrete. It is advisable to use a simple homemade concrete mixer or a ready-made commercial one.
Cinder blocks were and are one of the most popular materials for construction. various designs in construction. Their characteristic strength, as well as good thermal insulation properties, make it possible to build quickly and relatively easily and quite cheaply. Both a professional and an inexperienced mason can build from them.