How to make aerated concrete?

Aerated concrete is one of the types of aerated concrete, which has high technical characteristics, while its price is very budgetary. This building material can be easily made by yourself using special equipment.

Independent production of aerated concrete can be of help not only with low-rise individual construction, but also provide an opportunity to start your own business.

These building blocks are very popular as they have the following properties:

• low density, which is almost five times less than that of classic concrete and three times less than that of brick;
• water absorption is about 20%;
• thermal conductivity is 0.1 W / m3;
• withstands more than 75 defrost / freeze cycles (and this is 2 times higher than the indicator of a brick);
• high compressive strength allows the construction of two- and three-story houses;

• excellent sound insulation due to the porous structure;
• high class of fire resistance;
• it is easy to work with the material - sawing, hammering in nails;
• safe for both humans and the environment, since there are no harmful components in the composition;
• it is possible to create a cast-in-place structure based on aerated concrete blocks.

Even a beginner can make construction aerated blocks. The whole benefit of independent work lies in high productivity, a simple manufacturing scheme, affordable and inexpensive materials for mortar, while the result is a building material of very decent quality with excellent technical characteristics.

There are several options for the type of line for the production of aerated concrete blocks depending on the volume and conditions of placement.

• Stationary lines. They are located to generate from 10-50 m3 blocks per day. For the operation of such equipment, 1-2 workers are required.
• Lines by type of conveyor. They produce about 150 m3 per day, which ensures regular large volumes of production.
• Mobile installations. They are used for self-production of aerated concrete blocks anywhere, including directly at the construction site.
• Mini lines. This is an automated complex for the production of up to 15 m3 per day of aerated concrete blocks. The installation itself takes about 150 m2. The line requires 3 people.
• Mini-plant. This line is capable of producing gas blocks up to 25m3. It also requires the labor of 3 workers.

Stationary equipment is considered the most profitable and reliable, since all the difficult stages are automated here and manual labor is not necessary constantly. These lines use a mobile mixer, a special complex for preparing and storing solution, heating water and a conveyor for supplying components to the batcher. Stationary lines are productive (up to 60 m3 of finished blocks per day), but they require large areas for installation (about 500 m2) and are very expensive.

Conveyor lines implement a fundamentally different production model - aerated concrete batcher and mixer do not move, only molds move. The process is completely autonomous, but due to the high production rates, it will be difficult to maintain such a process on its own - it will take 4-6 people. Placed on an area of ​​600 m2, its cost starts at 3,000,000 rubles.This option is suitable for those who plan to produce blocks for the purpose of their further sale.

Mobile lines are the best option for self-production of blocks for individual construction. The main advantage is the compactness of the equipment, the machine takes only 2x2 m2. It can be placed in any convenient place: on a construction site, in a garage or even at home. The line consists of a compact mixer, a compressor and a connecting sleeve, which allows you to fill several forms at once. The equipment is serviced by one person. Prices for mobile units do not exceed 60 thousand rubles and consume relatively little electricity.

Mini-lines can be stationary and conveyor type. Such plants are produced by the Russian companies "Intekhgroup", "Kirovstroyindustriya" and "Altaystroymash". The package contents may vary slightly from manufacturer to manufacturer, but all models have the basic components (mixer, block and mold cutter). They can occupy an area from 10 to 150 m2. It will also be necessary to organize a separate place for drying gas blocks. Mini-factories very often act as a launching pad for those who decided to manufacture and sell blocks of aerated concrete. Most domestic manufacturers of this equipment do not complete it with autoclaves. However, in the first stages, you can do without it. It can significantly reduce the drying time of the blocks and increase the daily output of the plant.

It is very profitable to make aerated concrete blocks with your own hands not only for individual needs, but also for the sale and organization of a small business. Raw materials and tools for the manufacture of this building material can be purchased by hand, in specialized stores or directly from the manufacturer.

Aerated concrete can be made in two ways: with and without an autoclave. The first option involves the purchase of special equipment in which aerated concrete blocks are "baked" under high pressure and temperature. Thanks to this effect, the smallest gas bubbles appear in the pores of the concrete, which improve the technical characteristics of the resulting material. Such blocks are more durable and more durable. However, this method is not suitable for home use, since the autoclave is not cheap, and also due to the fact that it will be difficult to organize the technology correctly on your own.

Therefore, the second method is suitable for making blocks with your own hands, without the use of autoclave equipment. With this option, the drying of aerated concrete takes place in natural conditions. Such blocks are slightly inferior to autoclave blocks in strength and some other characteristics, but are quite suitable for individual construction.

For an independent installation of an installation for the production of aerated concrete, the following tools will be required:

• forms for concrete mix;
• concrete mixer for solution preparation;
• shovel;
• metal string.

You can also purchase special equipment that independently doses and prepares the mixture - this will significantly speed up the material production process.

The technology of self-production of aerated concrete blocks has three mandatory stages.

• Dosing and mixing of dry components in the required proportion. At this step, it is important to precisely follow the selected dosage, since when the ratio of the components changes, concrete with different technical characteristics can be obtained.
• Add water and stir the solution until smooth. At this stage, the pores formed in the mixture should be evenly distributed, so it is advisable to use a concrete mixer.
• Filling forms.Special compartments are only half filled with solution, since in the first few hours the active formation of gas bubbles continues, and the mixture increases in volume.

Then, after 5-6 hours after filling the molds, the excess mixture is cut off from the blocks using a metal string. The blocks then remain in the molds for another 12 hours. You can leave them on the construction site or indoors. After pre-hardening, the blocks can be removed from the containers and left to dry for several days before being stored.

An important step in the independent production of concrete blocks is the selection of suitable forms.

Containers for pouring aerated concrete can be as follows.

• Collapsible. You can remove the sides at any stage of block hardening. These structures require additional physical strength.
• Caps. They are removed completely using mechanized systems.

The material for making the molds can be different: metal, plastic and wood. The most in demand are metal containers, as they are distinguished by their durability and strength. They are produced in two types, depending on the volume (0.43 and 0.72 m3). Whichever recipe is chosen for the manufacture of blocks, the raw materials are required the same.

The components for the production of aerated concrete are:

• water (consumption 250-300 l per m3);
• cement (consumption 260-320 kg per m3);
• sand (consumption 250-350 kg per m3);
• modifier (2-3 kg per m3).

Some requirements are imposed on the raw materials for the production of blocks. The water should be of medium hardness with a minimum indicator of salinity. The cement for the mixture must comply with GOST. Preference should be given to M400 and M500 Portland cement. The filler can be not only river or sea sand, but also ash, waste slag, dolomite flour, limestone. If sand is used, then it should not contain organic inclusions, large amounts of silt and clay. The smaller the filler fraction, the smoother the block surface will be. As a modifier, in order to accelerate the maturation of aerated concrete, gypsum-alabaster, calcium chloride and water glass can act.

Making concrete blocks with your own hands is a long, but not very complicated process that will significantly reduce the cost of building materials. Subject to the proportions and manufacturing technology, aerated concrete blocks are practically not inferior in their performance to the factory ones and can be safely used for low-rise construction.

For information on how aerated concrete is produced on a mini-line, see the next video.