DIY aerated concrete at home: an overview of the manufacturing process and calculation of economic feasibility

Aerated concrete is a widely used and adaptable building material that is well-known for its low weight, superior insulating capabilities, and simplicity of application. You’re in the right place if you’ve ever wondered whether it’s possible to make aerated concrete at home. This post will walk you through the steps of the do-it-yourself manufacturing process, making each step easy to understand.

Aerated concrete can be a rewarding project to make at home, but it does require some basic equipment and careful planning. From gathering materials to mixing and curing the concrete, we’ll break the process down into manageable steps. You’ll find this guide to be useful and educational whether you’re a novice to construction projects or an experienced do-it-yourselfer.

Knowing whether or not to make aerated concrete economically is one of the most important things to do. We’ll look at the expenses of making your own aerated concrete versus buying pre-made blocks. You’ll know for sure by the end of this article whether this do-it-yourself method is cost- and time-effective for you.

Come along as we explore the world of do-it-yourself aerated concrete, learning the trade secrets of its creation and assisting you in making wise choices for your construction endeavors. Let’s begin this thrilling adventure of making your own aerated concrete blocks at home.

What is aerated concrete and what is its characteristics

You should first think about what aerated concrete is before learning how to make it at home. What characteristics does it possess, and is there any point in making a specific choice about it?

Basic properties and qualities

According to GOST, aerated concrete has to meet a number of requirements, the list of which is strictly limited. Let’s examine and evaluate them to see how significant and useful they are going forward. The table will be used by us.

Technical and physico-mechanical characteristics of aerated concrete:

Name of the indicator Value in accordance with GOST
Thermal conductivity From 0.09 to 0.38
Frost resistance From 15 to 35 cycles – for non -avoiding aerated concrete, from 35 to 150 cycles – for autoclave aerated concrete
Density D300-D1200
Brand of strength From B1.5 – for non-autoclaved aerated concrete, from 2.5 – for autoclaved
Vapor permeability On average – 0.2
Shrinkage From 0.3 mm/m2

Let’s start by focusing on the thermal conductivity index. Technical documentation states that the range is 0.09 to 0.38. Its numerical value will, however, actually be higher under operating conditions because the above is typical for products in a dry state.

  • The release humidity of aerated concrete varies within 25-30%.
  • Frost resistance indicates how many freeze-thaw cycles the product can withstand. Some manufacturers claim that this indicator for aerated concrete can reach 150, and the service life is up to 200 years.
  • Density can be different, it depends on the porosity of the block and some other factors. This indicator determines the scope of application of the material, we will talk about it in more detail later.
  • Vapor permeability is the ability of a material to exchange vapor. For example, if the humidity is high, aerated concrete is able to absorb it, and if the air is excessively dry, it is able to give it off. Thanks to this quality, the most favorable microclimate will be established in the room.
  • Shrinkage is a rather unpleasant phenomenon. However, the indicator of 0.3 mm / m2 is not so great. The appearance of cracks during shrinkage is a common phenomenon.

Types of material and products made from it

Let’s now discuss the various materials and products that can be produced by beginning the at-home production of aerated concrete.

Aerated concrete can be: based on density

  • Heat-insulating;
  • Structural and heat-insulating;
  • Structural.

The density of the first choice is between 300 and 400. It has a minimum thermal conductivity coefficient and is lightweight. Even the name of this type of aerated concrete—which is used as a heat-insulating material—speaks for itself.

The most common kind of insulation is thermal and structural. It ranges in density from 400 to 900. It is employed in the building of dividers and walls.

Structural: the most resilient kind. 1000–1200 is its density. But the material also has a high thermal conductivity coefficient, which offers more insulation. Items with a high load capacity are utilized in the construction of structures that reach heights of 12 to 15 meters.

The conclusion is self-evident: the thermal conductivity coefficient increases with density. Let’s look at how these indicators change in tandem using a table.

Dependence of aerated concrete’s density and thermal conductivity:

Type of aerated concrete Density Thermal conductivity in dry condition
Heat-insulating D300 0.09
D400 0.11-0.12
Structural and heat-insulating D500 0.12-0.13
D600 0.13-0.14
D700 0.15-0.18
D800 0.18-0.21
D900 0.20-0.24
Structural D1000 0.23-0.29
D1100 0.29-0.34
D1200 0.29-0.38

But there are other classifications as well. Aerated concrete can be autoclaved or not, depending on the hardening technique.

The final stage of production for autoclaved aerated concrete, also known as aerated concrete of synthetic hardening, involves processing the products in unique apparatuses called autoclaves, where high pressure and temperature are applied.

Under natural circumstances, non-autoclaved aerated concrete, also known as aerated concrete of hydration hardening, reaches technical maturity. To expedite the process, it is occasionally heated to a low temperature of no more than 100 degrees.

Kindly take note! Blocks for autoclaved hardening are only produced in factories.

GOST 21520-89 Concrete wall blocks with cells. Technical requirements allow products to be divided based on their geometry.

Gas blocks are separated into the following categories based on the accuracy category:

  1. First accuracy category. Permissible deviations in size for such blocks should be no more than 1.5 mm, diagonally – no more than 2. Products are laid on glue.
  2. Second accuracy category. More significant deviations are established for such products: up to 3 mm – in size, up to 4 mm – diagonally. Chips at the corners are also allowed. Laying is carried out both with glue and mortar.
  3. Third accuracy category. Such products are laid on mortar, which will undoubtedly lead to an increase in cold bridges. As a result, such gas blocks are usually used in the construction of outbuildings in the form of a garage or a barn. Permissible deviations: up to 5 mm – in size, up to 10 mm – chips at the corners (no more than two on one product).

Additionally, aerated concrete is separated based on the kind of binder used:

  • On cement;
  • On ash;
  • On slag;
  • On a mixed binder;
  • On lime binder.

The presence or absence of a siliceous component in the composition depends on its type.

  • Quartz sand;
  • Ash;
  • Other secondary industrial products.

Strengths of buildings erected from aerated concrete

Because aerated concrete has both advantages and disadvantages, it is not a material that works for everyone.

Let’s examine them, maybe beginning with the benefits:

  1. The products are quite light. This will significantly reduce the load on the foundation of the building.
  2. Aerated concrete blocks have large dimensions, which will undoubtedly speed up the process of erecting walls.
  3. The products are produced mainly using a mixture of lime, cement, water, sand and aluminum powder. They do not contain harmful and toxic substances. This indicates the environmental friendliness of the material.
  4. Fire resistance. Aerated concrete does not burn and does not interact with fire. Moreover, the products can be exposed to high temperatures for up to 2 hours.
  5. The material is easy to handle. It is easy to saw, grind and cut. At the same time, you do not need to use any highly specialized equipment. A simple hacksaw or saw will do.
  6. High frost resistance – a significant plus.
  7. The material has the ability to vapor permeability, which, in turn, provides the opportunity to establish an optimal microclimate.
  8. Soundproofing characteristics – also at a height. This will allow you to protect those in the room from extraneous noise from the outside.
  9. The ratio of strength and thermal conductivity indicators is optimal. In this regard, aerated concrete occupies a high position among materials intended for the construction of walls.
  10. Variability of interior and exterior decoration. The building can be faced with almost any materials, the main thing is to follow the technology.
  11. A large selection of manufacturers and sizes, can also be attributed to the advantages.

As you can see, the aforementioned qualities are more than enough to build a useful building with high performance indicators.

Disadvantages of products and options for their elimination

The primary drawback of aerated concrete is its tendency to become hygroscopic. The material’s open pore structure actually contributes to the increased moisture absorption. 25% is shown by the numerical indicator.

When low temperatures are common during the winter, the moisture that has accumulated inside the products can crystallize and start to destroy them from the inside out.

This issue can be resolved. Finishing can help shield products from the damaging effects of moisture. Furthermore, to keep moisture from penetrating the wall surface, the building’s interior finishing and facade cladding must be technically integrated.

The following are possible options:

  • If the facade is made without the use of ventilation, then the interior decoration must be sealed. For example, brick cladding can be combined with tile finishing inside.
  • When installing a ventilated facade, the presence of a sealed finish is not necessary, since the condensate will be released.

Other, less significant drawbacks of aerated concrete are:

  • The need to purchase special fasteners to fix the elements, and, if you want to fix particularly heavy objects – the need to plan the units and strengthen them. This applies, for example, to radiators or other products with a high level of tearing.
  • Fragility of products. This is especially noticeable during transportation and work. A certain number of blocks with chips and cracks may appear.
  • Shrinkage. This is typical for aerated concrete blocks. Cases of cracks appearing on finished walls are not uncommon.

Furthermore, these drawbacks can also be somewhat offset. For instance, take your time finishing so that any cracks won’t ruin the building’s appearance and you have time to fix them. Give the structure some time to settle.

Simultaneously, it is imperative to acknowledge the seasonal nature of the tasks. Since it’s not advisable to leave aerated concrete walls exposed for an extended period of time.

A practical and affordable way to make lightweight, long-lasting building materials for a variety of construction projects is to make aerated concrete at home. This post will walk you through every stage of creating aerated concrete, from assembling supplies to blending and curing. To assist you in deciding whether producing your own aerated concrete is more cost-effective than purchasing it already constructed, we will also offer a basic economic analysis.

Production of gas block

Now that we have a clear understanding of what aerated concrete is, let’s examine the production method.

There are several steps involved in the technology for making aerated concrete at home. However, let’s first go over the list of necessities for getting started on the project.

Calculation of pile foundation

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m.m 2 .m 2 .m 3 .22266.02 kg.kg/cm 2 .mm.mm.kg.33.54 mm.1.00 m.pcs.m.m 3 .kg.

Required set of equipment and materials

  • Cement. It is recommended to use a grade of at least 400;
  • Quartz sand. At best, it should be sieved, washed and dried. That is, it is necessary to get rid of impurities;
  • Clean water;
  • Quicklime
  • Additive for the production of aerated concrete: aluminum powder, as well as sodium sulfate and caustic soda.
  • Molds for blocks. They can be purchased ready-made, or built by yourself with your own hands.

The following are the basic manufacturing instructions: first, a pencil case is put together using boards. The general frame is divided into sections by inserting pre-made jumpers into them all the way along. Waterproof plywood is an option. Pre-cuts are made in the boards for fixing.

These cells’ sizes ought to line up with the blocks’ intended sizes. It is advised to construct multiple forms appropriate for the different needed sizes in order to expedite the production process.

Kindly take note! The solution is pre-lubricated with a unique compound to stop it from adhering to the forms. For instance, you could use one-third dilution of machine oil in water.

Regarding the units for creating the solution, you can buy a mobile unit that comes with a mixer, compressor, and connecting hoses to help connect the various pieces of equipment.

A unit like this can be used to plan a small production in addition to being used for one-time use. The amount of manufactured goods produced each day ranges from 10 to 20 m3, depending on the nature and specs of the machines.

You will also require devices to stop excess solution after gas formation in addition to the above.

Kindly take note! Weighing and measuring the proportions will need to be done separately if there isn’t a component dispenser. When doing this, exercise extreme caution because out-of-proportion actions will alter the attributes and quantitative measures of the final products’ quality.

Overview of the manufacturing process

The steps involved in making aerated concrete blocks at home are as follows:

  • First, mix the solution. Dry components are dosed and mixed together. Then add water, and mix everything thoroughly.

The approximate ratios of raw materials used in the manufacturing of aerated concrete without autoclaving

It is currently feasible to buy a ready-made mixture. The following ingredients make up the dry mixture used to produce aerated concrete: 20–60% cement, 0.1–0.2% microsilica, 32–75% mineral filler, 2-4% gypsum, 0.2-0.5% plasticizer, and 1-3% quicklime.

Using such a mixture extends the shelf life, speeds up the hardening process, and improves the technical characteristics of the final product. It can be used in a mini-factory to manufacture goods in addition to being used for domestic use.

Note: You can directly affect the density of subsequent products by making the mixture yourself. Their density and thermal conductivity will decrease as their porosity increases.

  • Further, the technology for the production of aerated concrete blocks involves pouring the solution into molds. You should not fill them completely to the brim, but be sure to take into account that soon the mixture will begin to swell and the excess will spill out. Filling is done approximately 1/2.
  • After this, the process of gas formation begins.
  • The next step is to remove excess mixture. For this you can use, for example, metal strings. This is done in about 5-6 hours.
  • After another 12-14 hours, the products can be stripped. If you lightly tap on the forms, the aerated concrete will come off better.
  • Non-autoclaved blocks reach their technical strength after 28 days.
  • They can harden indoors or outdoors.

Kindly take note! It’s critical to consider the possibility that the products won’t always be flawless. Additionally, since there is no set formula for proportions, choosing them may also require some raw materials. Even though the process is straightforward, making aerated concrete by hand involves some expertise.

You can learn more about each stage of production by watching the video included in this article.

Comparison of self-made and factory-made products

As was previously mentioned, hydration-hardened aerated concrete can be made at home, and autoclaved aerated concrete can be produced in factories.

Of course, there will be technical and physical differences between these products. And let’s take a quick look at the industrial release process of products before comparing their properties.

There are two kinds of lines that can be utilized: conveyor and stationary. In the second scenario, there is very little human involvement and everything occurs automatically. Typically, the machines need to be operated by multiple operators.

Similar to home production, the components are combined using dispensers, transferred to a gas concrete mixer, and then poured into molds during the manufacturing process. The product layer is then turned over and sliced to the appropriate dimensions. The autoclaving step is the last one.

Naturally, there is a major reduction in both labor and time costs. Production volumes can reach 200 m3 per day, depending on the type of equipment. Large spaces are needed for warehouses and production. We will use the table to compare self-made products that are autoclaved and those that are not.

Production technology of aerated concrete: contrasting manufactured and homemade goods

Name of the property (characteristic) Meaning and comments
Strength Autoclaved aerated concrete is more durable. GOST requirements for hydration-hardened aerated concrete are not so high. Home production usually involves the production of blocks with a density of 400-500.
Thermal conductivity The ratio of strength and thermal conductivity indicators for an autoclave is much better. The thickness of the wall, while maintaining the same indicators, differs by 20-25 cm. That is, a wall erected using an autoclave should be at least 40 cm, and when using a non-autoclave – at least 65 cm.
Frost resistance And in this indicator, autoclaved aerated concrete is ahead. It can withstand up to 150 freeze-thaw cycles. Non-autoclave, in turn, up to 50.
Fragility Hydration-hardened products are more fragile. They also have lower indicators bending strength.
External data Autoclane aerated concrete – white. Non-autoclaved – more gray
Performance characteristics Durability is typical for both products, but the palm again belongs to synthetic hardening products. According to the manufacturers, the service life can reach 200 years. Non-autoclaved can boast an indication of 50 years.
Environmental friendliness Both materials are manufactured using raw materials that do not contain harmful and toxic substances. Their environmental friendliness index is 2.
Fire resistance Both products do not burn
Possibilities of facade cladding and interior decoration Both autoclaved and non-autoclaved aerated concrete can be finished using almost any materials. In this case, it is only necessary to strictly adhere to the technology and take into account the compatibility of materials with each other. That is, the interior decoration must match the exterior or vice versa.

As you can see, the autoclane factory unit outperforms an independent manufacturer’s aerated concrete in every way. But, the choice is actually fairly good when budget savings are considered. In any event, a good outcome and a long-lasting building will be created if all requirements are satisfied.

Profitability of production

Production’s profitability and viability from an economic standpoint depend on several factors.

Several of them:

  • Investments associated with the purchase of equipment;
  • Cost of raw materials. Agree, the price can be different;
  • Production waste and defective products can lead to unplanned expenses;
  • The desired volume and purpose of production (for yourself or a mini-business)

Let’s go straight to the calculations now.

  • 1 m3 of blocks costs an average of 3,200 rubles.
  • Let"s assume that we need to purchase 90 m3 of products for building a house.
  • 90 * 3,200 = 288,000 rubles we will need to purchase finished aerated concrete products.
  • The most budgetary option of equipment (possibly used) will cost 50,000 rubles. Raw materials, water and electricity costs will be about 2000 for 1 m3 of blocks.
  • 2000*90+50000=230000. The same 90 m3 of self-made blocks will cost this amount.
  • Result – savings will be 58000.
  • But non-autoclaved aerated concrete is cheaper, about 3000 rubles per m3. Then we count again: 3000*90=270000. And it still comes out more expensive.

In the unlikely event that you choose to launch a side project, you may make a respectable living. The equipment will pay for itself in a few months if you are able to quickly sell the manufactured goods.

If you choose to continue making the blocks by hand, be ready to put in a lot of time and work.

Step Description
1. Gather Materials Collect cement, lime, sand, water, and aluminum powder. These are the basic components for making aerated concrete.
2. Mix Ingredients Combine cement, lime, and sand in a mixer. Gradually add water to achieve a smooth consistency.
3. Add Aluminum Powder Introduce aluminum powder to the mix. This will create gas bubbles, giving the concrete its aerated property.
4. Pour into Molds Pour the mixture into molds of the desired shape and size.
5. Let it Cure Allow the concrete to cure for several hours until it solidifies.
6. Remove from Molds Carefully remove the aerated concrete blocks from the molds.
7. Dry Completely Let the blocks dry thoroughly before use. This ensures maximum strength and durability.
Economic Feasibility Consider the cost of materials, time, and labor. Compare it to the price of purchasing pre-made aerated concrete to determine if it"s cost-effective.

For individuals who want to customize their construction materials and reduce building costs, making aerated concrete at home can be a fulfilling project. Strong and lightweight building blocks that are appropriate for a variety of construction applications can be produced by adhering to a simple manufacturing process. Preparing the proper mixture of cement, lime, sand, and water, adding aluminum powder as a foaming agent, and letting the mixture cure properly are the crucial steps. You can get reliable results that are comparable to those of commercially available aerated concrete blocks with a little practice.

It’s important to think about the economic viability before starting production. You can decide if making aerated concrete at home is a cost-effective option by calculating the costs of raw materials, equipment, and labor. Producing your own blocks can result in significant savings over time, especially for large projects, even though the setup costs may be high at first. The satisfaction of producing your own building supplies and the ability to manage block quality can also raise the total value.

All things considered, DIY aerated concrete can be a useful option for house builders and do-it-yourselfers. It has the benefits of customization, quality control, and cost savings. You can determine whether this method works for your building needs by carefully planning and carrying out the manufacturing process and thoroughly analyzing the financial aspects. Making aerated concrete at home can be a profitable and successful addition to your construction projects if you take the proper approach.

Video on the topic

Production of aerated concrete Inntechgroup

DIY aerated concrete. Part two. Result.

Aerated concrete block composition.DIY aerated concrete block.#aerated concrete blocks

DIY aerated concrete at home. 3 times cheaper purchased. SUPER method.

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Marina Petrova

Candidate of Technical Sciences and teacher of the Faculty of Construction. In my articles, I talk about the latest scientific discoveries and innovations in the field of cement and concrete technologies.

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