Do-it-yourself expanded clay concrete blocks: how to get high-quality material

If you’re willing to do some DIY work, making your own expanded clay concrete blocks can be a satisfying project. These blocks are a fantastic option for a variety of building applications because of their superior thermal and sound insulation qualities. You can make excellent blocks at home with a little knowledge and a few simple tools.

We’ll take you step-by-step through the expanded clay concrete block making process in this guide. We’ll go over all the necessary procedures, such as properly mixing the ingredients and curing the blocks. This guide will assist you in achieving dependable and long-lasting results, whether you’re building a new wall or searching for an affordable building solution.

By the time you’re done, you’ll know exactly how to make these blocks on your own, which will save you money and give you the satisfaction of doing it yourself. Now let’s get started and learn how to make superior expanded clay concrete blocks at home.

What is expanded clay concrete

This kind of concrete is lightweight. It includes expanded clay, which functions in the same way as crushed stone in the heavy mixtures we are used to.

When expanded clay and cement are combined, the material takes on unique qualities.

1. low specific gravity (density), which allows you to make and lay large blocks;
2. good thermal insulation properties, walls made of such blocks do not require additional insulation;
3. The material is water-resistant superior to ceramics and silicate, since cement only strengthens in the presence of moisture;
4. it is non-flammable;
5. Expanded clay concrete is well plastered and finished in other ways;
6. the material contacts well with heavy concrete structures, which cannot be said about other types of thermal insulation.

Owing to the pores in the filler, expanded clay has fewer strengths and is less resistant to frost than heavy concrete.

Composition of expanded clay concrete

The ideal sand for expanded clay concrete, as well as any building mortar, is made from crushed screenings.

The composition of expanded clay concrete is nearly identical to that of heavy concrete and consists of the following:

1. cement;
2. fine filler — sand;
3. coarse filler — expanded clay, we will talk about it below;
4. additives, modifying the properties of the mixture and material (optional).

Water is another component that is needed for preparation and hardening. We will discuss the composition’s selection at a later time. Microfiber (polymer, glass, basalt, etc.) can also be added to the mixture to strengthen the blocks. p.) that will strengthen the rock.

The quality and lack of foreign impurities requirements for the components are the same as those for regular concrete. Using washed sand is advised.

What is expanded clay

One artificial building material is expanded clay. It is created by shaping clay and shale mixture into granules, which are then burned.

• During sintering, gases are released, which form closed pores inside. Moreover, the outer layer remains almost monolithic.
• Thus, despite the presence of an internal air space, expanded clay granules weakly absorb water. In addition, expanded clay is cheaper than all other porous fillers, and has good strength.
• When purchasing expanded clay, you need to take into account its brand by density – the lower the density, the lower its thermal conductivity, but also its strength.

GOST states that expanded clay is separated into fractions based on the millimeter size of the granules:

1. from 5 to 10;
2. from 10 to 20;
3. from 20 to 40 mm.

Generally, expanded clay is offered for sale in large quantities or packaged in various items, such as large bags like the ones shown in the image below. Using the first two fractions or their mixture (which is even better) is preferable for block production. However, you can also add a small amount—between 20 and 40 mm—if you want to create solid blocks without any internal voids.

Expanded clay concrete production technology

With the exception of the large filler, which is different, the technology used in the production of expanded clay concrete blocks is essentially the same as that of heavy mix. It involves the following operations:

1. Mixing the components.
2. Laying the solution in the formwork or mold.
3. Compacting the mixture.
4. Forming the block and removing the formwork.
5. If it is necessary to speed up the process, steaming is used.
6. If steaming was not carried out, then the products or structures are kept with special care until they reach the grade strength.

The only distinction is that gravity mixers are less effective than forced mixers when making expanded clay concrete by hand. This is because light expanded clay granules mix less well than heavy gravel or crushed stone when they fall from a height after being caught by a gravity concrete mixer’s blades.

What is needed for home production of expanded clay concrete blocks

Naturally, a minimal amount of equipment is required in addition to the materials.

Let us examine two possibilities:

• you are going to make a small number of blocks for a small building one-time;
• you need to put the production of expanded clay concrete blocks with your own hands on stream due to the large volume of construction, or the plans include the sale of blocks.

For a small volume of production

Almost all owners have a gravity concrete mixer, which is more than enough for small-scale production.

You can get by with the least amount of equipment if, for example, you need to make several hundred expanded clay concrete blocks to build a garage.

These could be as follows, to put it simply:

1. Your existing gravity concrete mixer. For high-quality mixing, the operation should be carried out not for two or three minutes, as for heavy concrete, but one and a half to two times longer.
2. Molds or a machine for producing expanded clay concrete blocks with your own hands.
3. Vibrating table – in extreme cases, you can compact the mixture with a rammer, but this will make the process longer and more labor-intensive. In addition, when working with expanded clay concrete with a rammer, you need to accurately calculate the force so as not to crush the granules.
4. Tool for loading and dosing components – carts, buckets, shovels, etc. p.

If you are going to put production on stream

An illustration of production planned for a respectable volume; materials and blocks are even moved using an electric hoist.

• In this case, it is advisable to use a forced-action concrete mixer. It is advisable to mechanize the process of transporting components, mixtures and finished products.
• The easiest way to do this is to mount a beam crane on the site, or purchase an electric car with a front lift.
• Also, to speed up the process, and in order not to occupy a large area for the landfill on which the manufactured blocks will harden, you can mount a steaming device (more on this below).

Let’s examine each piece of gear in more detail.

Concrete mixer

It has a conventional design. For expanded clay concrete, a forced mixing device works better, as was previously mentioned. We choose the mixer’s capacity so that we can shape the prepared portion of the mixture and let it harden for one to two hours.

Vibrating table

This is the most expensive unit needed to produce blocks, excluding the mixer. However, unless you use an immersion vibrator, which is slightly less expensive, when producing solid products, you cannot do without it. However, this strategy will impede the manufacturing process, making it unfeasible.

Purchasing a vibrating table from a construction tool store is a challenging task. But ordering it is simple. This device has a starting price of 10,000 rubles. Moreover, you could make it yourself.

There are just a few units in the basic design:

1. base (frame);
2. the platform on which compaction occurs (the table itself);
3. shock absorbers on which the table is mounted, you can use springs from a car suspension, suitable rubber cushions;
4. vibrator, instead of an industrial device, you can install a motor with an eccentric on the shaft. Or even better – a separate eccentric connected to the motor via a belt drive.

Having two or more vibrators is desirable for higher quality work. We choose the size of the table so that it can hold the maximum number of forms or a block-making machine.

Pay heed. The issue of design resonance may come up when creating a vibrating table on your own, particularly if there is only one vibrator. It manifests itself as a sharp increase in vibration amplitude on the table, which pulls the base along with it and can even push the entire unit out of its position. By adjusting the engine rotation speed, gear ratio, or mass of the load on the eccentric, you can eliminate this phenomenon.

Forms

With the least amount of tools, the simplest forms are simple to create. For your production, you have a few options.

• Made from wood or a combination of it with other sheet materials, for example: a wooden frame, and tin or textolite walls. The tree will not last long, but for a small series it is quite an acceptable option.
• Make it from metal if you have a welding machine and skills. With proper care, metal forms can last for several years, they are easy to lubricate and clean.

Suggestions. Molds with detachable sidewalls should not be made; they are less dependable. The workpiece can be effortlessly extracted from the mold when the mixture composition is chosen appropriately.

• Buy ready-made metal or polymer molds.

Another method for creating molds is to use fiberglass. But the labor required is excessive. Make a model of our block and glue it together using multiple layers of fiberglass and epoxy resin to create a mold.

Machine for making blocks

It is designed to produce blanks for multiple blocks at once. If vibrators are integrated into the machine, it either only completes preliminary molding or compaction of the mixture happens right away.

Either purchase a pre-made machine or attempt to build one yourself, as demonstrated in the article’s video. Its design is highly customizable.

The most basic and prevalent unit among the following:

1. Block form — combinations of several forms.
2. Device for loading concrete mixture — trays or conveyors for feeding concrete into all forms at once.
3. Devices (usually with manual drive) — for preliminary compaction by pressing the mixture, and removing the blank from the form.

High-quality expanded clay concrete blocks can be made at home by following exact mixing and curing procedures and utilizing the proper material mixture. Make sure you use pure, premium expanded clay aggregate and adhere to the proper cement to water ratios. Strong, long-lasting blocks require careful mixing, mold preparation, and curing procedures. By keeping an eye on these specifics, you can create dependable and efficient building materials at home.

Concrete volume calculator

Topic	Description
Introduction	Learn how to make high-quality expanded clay concrete blocks at home. This guide covers the basics of materials, mixing, and molding.
Materials Needed	Expanded clay aggregates, cement, sand, water, and any required additives. Each material plays a role in ensuring the strength and durability of the blocks.
Mixing	Properly mix the expanded clay aggregates with cement and sand. The ratio of these materials affects the block’s quality. Use a reliable mixing method to achieve a consistent blend.
Molding	Pour the mixture into molds to shape the blocks. Ensure the molds are clean and properly oiled to prevent sticking and ensure smooth surfaces.
Curing	Allow the blocks to cure in a controlled environment. Proper curing improves the strength and durability of the blocks.
Quality Check	Inspect the blocks for any defects such as cracks or uneven surfaces. Testing their strength and density can ensure they meet the desired quality.
Conclusion	Making your own expanded clay concrete blocks can be rewarding. With the right materials and techniques, you can produce strong and reliable blocks for various construction needs.

When you take the time to adhere to best practices, creating your own expanded clay concrete blocks can be a satisfying project. You can make premium blocks with outstanding durability and insulation by carefully choosing your materials and adhering to exact mixing ratios. Recall that consistency and close attention to detail are essential for success at every stage of the procedure.

Once your concrete and expanded clay aggregate have been combined, make sure the curing process is properly handled. An appropriate curing process will make a big difference in your blocks’ durability and strength. Take your time and give the blocks enough time to set and completely dry.

With the right techniques and a bit of patience, you can create expanded clay concrete blocks that not only meet your construction needs but also stand the test of time. By adhering to these guidelines, you"ll achieve high-quality results and gain valuable experience in the process.

Video on the topic

Expanded clay concrete mixture consumption per block

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Expanded clay concrete blocks with your own hands, using the "Nesushka" machine./

Expanded clay concrete blocks. Composition.