Expanded clay blocks are a lightweight building material used for erecting walls of various buildings. Despite the small mass, they are environmentally friendly and durable. It is remarkable that the manufacture of expanded clay concrete blocks can be carried out independently. This will significantly reduce construction costs. At the same time, there will be no need to doubt their quality if made from good source material. Also, many may have a question about which machines for the production of expanded clay concrete blocks you need to choose. More on this later.
Technical characteristics of expanded clay blocks
This building material is endowed with great strength. In tests, expanded clay concrete showed that it can withstand a load of up to 20 Mn / m². Depending on the strength, there are grades of the following modifications 100, 150, 200.
Expanded clay is an excellent heat insulator. It is resistant to fire, water, (moisture absorption is not more than 7%). It is also frost-resistant and provides good sound insulation.
Buying building material is the easiest solution, but it will require considerable funds. To save finances, it is possible to organize the production of expanded clay concrete blocks independently. This can be done right at the construction site. In addition to savings, own production is justified by the fact that you can be calm about the quality of products.
Advantages of expanded clay blocks
The specified material, in comparison with foam and aerated concrete, has the following advantages:
- Competitive value.
- Water resistance and constant moisture content (ranging from 6 to 10%).
- Thermal conductivity.
- Resistance to temperature extremes and frosts.
- Fire resistance.
- Excellent vapor permeability, which allows you to adjust the level of humidity in the house.
- Resistant to rust and rot.
- The absence of aggressive substances that cause corrosion of metal parts.
- Excellent thermal insulation.
- The walls of these blocks are simply lined with various finishing materials.
- They are not affected by fungus, microorganisms, insects, mold.
- No need to apply a thick layer of plaster and install the grid.
- These blocks are endowed simultaneously with the positive properties of stone and wood.
- The surface of this material does not need preparation for finishing.
The mass of expanded clay blocks is 2.5-3 times lower than concrete. This can significantly reduce the weight of the building and save on the construction of the foundation.
Compared to brick, the mass of expanded clay concrete blocks is 2 times less. Installation is much faster. This is due to the fact that the volume of one block is equal to the volume of seven bricks. Therefore, the use of this material will reduce the cost of work by 40%.
Therefore, expanded clay concrete blocks can improve most of the technical and economic indicators of a building under construction, reduce the cost of building a foundation, and improve living comfort. This is important.
Mixture composition
Expanded clay blocks consist of several obligatory components. Firstly, it is expanded clay, which is used as the main material. Secondly, cement (suitable for the M400 brand), water and sand are the binders.In this case, the presence of each component is necessary. It is necessary to choose expanded clay sand of fine screening, since it is the best option for this type of product.
For the production of high-quality and strong blocks, special additives are used. This is important to know. To increase frost resistance, saponified wood resin is mainly added. The solution will bind better if lignosulfonate is used. The plastic properties of this material can also be affected by ordinary washing powder. He put one teaspoon in one bucket of water.
Proportions
The components are mixed in the following proportions: expanded clay - 6; sand - 3; cement - 1; water - from 0.8 to 1 (depending on the humidity of the sand). This process is carried out in stages, namely:
- Initially, water is poured into the concrete mixer.
- Then expanded clay is poured.
- Next is sand and cement.
- After everything is mixed for 1-2 minutes in the specified equipment.
The resulting mixture should not fall apart and keep the volume.
Required conditions for the organization of this production
In this case, you will need:
• A room in which there is heating, ventilation and electricity, as well as a flat floor.
• Availability of an open area for storage and drying of products.
Equipment for the production of expanded clay blocks
In order to organize the production process of these products, you will need:
• Vibrating press (vibrating machine) or vibrating table.
• Concrete mixer.
In this case, it would not hurt to figure out how the machine for the production of expanded clay concrete blocks works. The choice in this case depends on individual capabilities and desires.
Vibrating table is a reliable mechanism on which the installation of a removable unit - forms - is carried out and the vibrator is fixed. Their price is not high, they provide good performance. These designs are designed for the manufacture of one or more forms. However, you need to know that this equipment for the production of expanded clay concrete blocks is largely designed for manual labor.
Vibrating machines are a complex structure. However, working on them can be much more efficient and easier. They fixed on the frame a fixed block form. Vibration in this case is transmitted directly to it. Due to the use of the squeeze punch, a smooth and even surface of the produced block is guaranteed. Vibrating press for the production of expanded clay concrete blocks is an integral part of this machine. The cost of such equipment is high, but if you pay attention to the indisputable advantages of its use, then it is understandable.
It is worth noting that such equipment for the production of expanded clay blocks as a concrete mixer may be needed.
Production of expanded clay blocks in the home
Consider this process in more detail. Before making a claydite-concrete mixture, it is necessary to prepare forms that are pallets made of plastic or metal sheet. They should have a flat surface. You can also use wooden forms made of boards in the shape of the letter "G". In this case, the resulting building material will be textured. The dimensions of the blocks are mainly 39x19x14 cm.
The production process of blocks is carried out in 4 stages.
- All the ingredients are mixed. The most important thing is to keep the right proportions. Sand should be 3 parts of the total. Water can be poured 0.8-1 part. The same amount of cement will be needed. But expanded clay needs 6 parts. Important is the sequence with which the available components are loaded into the concrete mixer. First, water is poured, then expanded clay is poured, and then cement and sand are added.
- After mixing well, the mixtures begin molding - for example, using a vibrating machine. Such equipment for the production of expanded clay blocks is the most popular. The manufacture of blocks takes place directly in it.A steel plate is placed in the molding, and then the resulting solution is already poured. After filling, turn on the engine for vibration. Excess mixture is removed.
- After that, the plate with the form can be lifted. To do this, scroll the handle of the machine. As a result, an appropriate expanded clay block is obtained.
- Then the workpieces that have turned out are dried. After complete hardening of the solution, steel plates are removed.
Tip
Before you start manufacturing claydite-concrete blocks, you need to calculate their cost. This process is simple if the price of all available components is known. In this case, it is necessary to determine the cost of the finished unit of material. In general, calculations will indicate that the independent production of these blocks is much cheaper than the purchase of finished ones.
Attachments
When organizing a bottom business, the following costs will be required:
- When purchasing equipment - 339.12 thousand rubles.
- Transportation costs - 40 thousand rubles.
- When purchasing raw materials - 100 thousand rubles.
- For registration in the INFS, opening an account, other expenses - 50 thousand rubles.
The result is 529.12 thousand rubles.
Revenue
In this case, everything should be calculated correctly. In the production of these products 110 pieces / hour, loading equipment 6 times per hour, the number of shifts per month - 22, production - 14 520 pieces, the wholesale price of products - 36 rubles. for 1 pc. revenue is 522 720 rubles. However, this amount may vary depending on certain changes made individually.
Costing
In this case, the basis is the number of blocks that are produced per hour. Given the cost of the components that make up the product, and the cost of electricity, the cost of 110 expanded clay blocks will be 1978.78 rubles. It turns out for 1 pc. - 17.99 p. Calculation of direct material costs for 1 month. for production 14 520 pcs. these blocks is 261,215 rubles. (14 520 p. X 17.99 p.)
Common expenses
The following should be considered here:
• Salary costs (based on 3 people) - 60 thousand rubles.
• For social deductions - 18 thousand rubles.
• For rent of premises and open territory - 50 thousand rubles.
• For other administrative expenses - 20 thousand rubles. In this case, utility and bank payments, the Internet, and communications are implied.
• Other necessary expenses - 15 thousand rubles.
As a result, we get - 163 thousand rubles.
Profit
In this case, the following calculation comes out:
From 522 720 rub. we take away 163 000 rub. and 261,215 rubles., we get 98,505 rubles.
As a result of this, it turns out that the investment will pay off within 6 months.
Total
After reviewing the foregoing, everyone can learn about how the production of expanded clay concrete blocks looks, what advantage this material has and how to choose suitable equipment.
