Installation of expanded clay concrete partitions: a step-by-step plan

For both residential and commercial buildings, expanded clay concrete partitions are a popular option because of their strength, ability to insulate sound, and simplicity of installation. In addition to being lightweight and thermally efficient, these partitions offer an efficient means of dividing spaces. Whether you’re an experienced builder or a do-it-yourselfer, knowing the procedures for installing these partitions will help you produce results that look professional.

It’s crucial to gather all required tools and materials before beginning the installation. Among other necessities, you’ll need mortar, expanded clay concrete blocks, a trowel, a level, and a measuring tape. In order to guarantee a seamless installation process and a stable, level final structure, careful planning and preparation are essential.

Setting up expanded clay concrete partitions starts with defining the space where the partition will be constructed. Precise measurements are essential to guarantee that the blocks fit precisely and the partition lines up with the current floors and walls. After marking the layout, you can start preparing the mortar and placing the first row of blocks, being cautious to place them evenly apart.

It’s crucial to verify each row’s alignment and level as you assemble the partition. This will stop any unevenness or leaning that could damage the partition’s structural integrity. Maintaining a straight and sturdy build can be aided by routinely using a level and making necessary adjustments. The overall strength of the partition will also be increased by making sure the mortar joints are uniform and well-filled.

It’s crucial to give the mortar enough time to cure after installation is finished. By doing this, you can be sure that the partition is stable and prepared for any final details, like painting or plastering. It is important to adhere to the manufacturer’s recommendations for the particular materials you are using, as proper curing times can differ. These instructions will help you build a long-lasting and useful expanded clay concrete partition that improves the appearance and use of your room.

Step	Description
1	Plan the layout
2	Prepare the area
3	Build the frame
4	Install expanded clay concrete blocks
5	Apply mortar
6	Check alignment
7	Finish the surface
8	Clean the area

What are the advantages of expanded clay concrete

The qualities of the material used to make hollow expanded clay concrete block partitions give them a number of benefits, including:

• This material is noticeably lighter than concrete (has a lower bulk weight), which significantly simplifies the installation of structures based on it.
• In terms of mechanical strength, such blocks are comparable to concrete analogues, not inferior to them in resistance to cracking.
• The use of expanded clay concrete is justified by its fire resistance (with strong heating, the load-bearing capacity of the products does not decrease).
• Buildings made from such blocks are characterized by good vapor permeability (the wall made from them “breathes” to its entire depth).

• Products made from it are distinguished by enviable frost resistance and can withstand about 100 cyclic freezing and subsequent thawing.
• The environmental friendliness and low cost of expanded clay concrete blanks are especially in demand in the construction of residential buildings.

It’s also critical that hollow expanded clay concrete partition blocks can be produced on-site; to do this, some basic equipment must be placed close to the structure that needs to be built.

The majority of finishing materials, such as ceramic tiles, laminated plastic, plaster, or natural wood, are noted by builders to have good adhesion.

Types of expanded clay concrete blocks

Expanded clay concrete partition blocks are commonly categorized based on the subsequent criteria:

• by density, which determines the load-bearing capacity of the product;
• by purpose;
• by shape and structure of the material

The ease of production of expanded clay concrete blocks lets you establish the specifications according to the intended use of each unique kind of product. The size and form of the block are crucial factors to take into account when thinking about partitions.

The following designs are possible for a basic expanded clay concrete partition block based on these specifications:

• Crested.
• Straight.
• L-shaped (corner).
• Simple.

Blocks can also be hollow or solid, and they can be shaped like crossbars and lintels. These products come in a wide range of sizes and shapes, so you can build partitions of any complexity from them.

Their area of application is indicated by the product name; they can serve as a wall or partition, ventilation system, or foundation, depending on their intended use.

Marking and characteristics

For the production of expanded clay concrete blocks, expanded clay and Portland cement are used, processed using the well-known pressing method on a vibrating table. In accordance with GOST 6133-99, 10180-90 and 12730.1-78, according to their mechanical characteristics, they belong to the class of lightweight concrete.

As per this document, they are identified by the following marking:

• Wall products are designated with the symbol "C".
• Blocks from which hollow partitions are made are marked with the letter "P".
• Facing and row (used for finishing) – "L" and "R", respectively.
• Corner block blanks are designated as "UG".

The material’s density, indicated by the letter "D," is another of these products’ important technical specifications. For the majority of expanded clay concrete block types, this indicator falls between D500 and D900.

This range of products varies not only in terms of density but also in terms of weight and thermal conductivity. For instance, a product with a density of D900 weighs roughly 17 kg, while an expanded clay block with dimensions of 390x190x180 mm and a density of D500 weighs roughly 12 kg.

Blocks made of expanded clay concrete have a maximum length of 40 cm, a maximum width of 19 cm, and a maximum height of 20 cm.

Installation of a partition made of expanded clay blocks

Mortar for expanded clay concrete

Expanded clay concrete blocks are laid using either pre-made solutions or powder mixtures that are purchased and mixed before work begins. In the first instance, you should mix them according to the directions on the package.

Please note: For these purposes, a concrete mixer located near the place where the partitions are laid is best suited.

The foundation of homemade solutions is the finest grade cement (not less than M400), to which the necessary amount of sand that has been cleared of lumps and debris is added. The necessary strength of the masonry determines the ratio of components in the solution, which is typically chosen to be 1 to 3.

Before being used, the cold water in the mixture is pre-filtered, or free of large debris particles. Its percentage in the final mixture shouldn’t be more than 25% of the total mass.

Experts advise following these guidelines when making the solution yourself:

• The composition is prepared immediately before use (due to the possibility of its hardening).
• For this, it is more convenient to use a small-volume concrete mixer.
• First, a little water is poured into it, and then the amount of sand and concrete calculated for one batch is poured.

The remaining amount of water is added to the composition after it has been well combined.

Preparing the base

The base, which is essentially a layer of waterproof concrete, is prepared before expanding clay concrete partition blocks are installed. You can use the following for these purposes:

• ordinary roofing felt;
• glass insulation;
• any other laid roll material.

The work area needs to be leveled with a layer of screed and cleaned of any debris and leftover coating before the insulation is installed. The concrete is then covered with a layer of cement mortar, and waterproofing is layered on top of that.

Bricks or FSB are used as a base if a plinth needs to be arranged beneath the partition.

How to properly lay expanded clay blocks

Prepare a set of blanks that have already been adjusted in size and place them close to the work site before you begin laying. Next, you’ll need to decide on a masonry pattern: half a block or a full block (the latter is typically chosen when building partitions).

The following steps are involved in the process of laying expanded clay concrete blanks technologically:

• First, corner (beacon) blocks are installed.
• Then a string is stretched between them to control the correctness of the masonry.
• After this, be sure to apply the solution (not glue)!) the first row of blocks is laid.

Crucial! In order to level the voids, you should begin at the base’s highest point and widen the gap (seam).

• The second and subsequent rows are laid with a slight offset, and the thickness of the seam should be at least 1 cm.

Checking the evenness of the laying after finishing the next row is important because uneven block sizes could cause it to become disrupted. It is important to remember to reinforce the structure every three to four rows using a specific type of mesh.

Dressing

The connection of the partition with the building’s supporting structures, which is completed throughout the wall’s thickness, should be your top priority when installing blocks. Drilling holes into them and inserting reinforcing bars and mortar into them helps to organize it.

It is necessary to ensure ligation between rows when laying expanded clay concrete piers and partitions. To do this, move the blocks in each row by half their length. This will be roughly 19 cm, given that a typical block blank has a standard size of 38 cm.

By evenly distributing the load across the entire structure, bandaging helps to increase the strength of expanded clay concrete structures. This technique has long been used to reinforce other building structures as well as lightweight partitions.

Doorway

Door units must be built in when building expanded clay concrete partitions, and tongue and groove panels are a preferred design for these. Should they be accessible, the subsequent tasks must be completed:

• Securely fasten the side walls, for which a reinforcing rod is used, laid in niches on the sides of the opening.
• Then their sections are filled with mortar, on top of which a pre-prepared metal lintel is laid.

Additional details: Aligning the edges of solid expanded clay concrete blanks suffices; reinforcement is not required.

Special lintels are available for hollow blocks that are concealed within the pier’s structure and perfectly fit with them.

Completion of the construction of walls

A wall expanded clay concrete partition is not built all the way to the ceiling when it is finished. It is necessary to leave a space of approximately 1-1.5 cm between the ceiling and the top row of blocks; this space is then filled with polyurethane foam.

The working gap is required to stop expanded clay concrete partitions from deforming as a result of potential ceiling slab vibrations.

Expanded clay concrete partition installation is a simple procedure that improves your space’s insulation and structural integrity. This guide offers a detailed, sequential plan to assist you with every step of the installation process, from setting up your supplies and workspace to applying the finishing touches. This comprehensive but approachable method guarantees that you can confidently finish your partition installation successfully and efficiently, regardless of your experience level with DIY projects or building projects.

Mortar or glue

The following should be taken into consideration when thinking about unique mixes and compositions used for laying blocks:

• When working with most expanded clay concrete materials, preference is given to special adhesive compositions.
• When laying the first row of blocks, it is best to use cement mortar.
• A special mixture used for laying tiles can be used as glue.

It is noteworthy that the quality of expanded clay concrete product installation only improves with the use of an adhesive composition.

Monolithic partitions

Expanded clay concrete monolithic partitions are produced by a standard process that involves pouring a pre-made mixture into a mold from a specific formwork. Metal fences are added on both sides to ensure that the internal and external surfaces are of the necessary quality.

There are drawbacks to this kind of expanded clay concrete product as well as some benefits. Their drawbacks include the need for heavy formwork during production, labor-intensive manufacturing, and a high number of one-time procedures.

One of their benefits is that, depending on the structure being built, they can be produced in any size and shape. Furthermore, monolithic partitions have a longer lifespan (when compared to a structure composed of individual blocks).

Please take note that additional reinforcement using approved techniques is permitted in expanded clay concrete products to improve their strength characteristics.

Even with all the benefits mentioned, these kinds of partitions are hardly ever utilized in real life.

Expanded clay concrete partition installation is a simple procedure that can greatly enhance a space’s usability and appearance. Even people with no prior construction experience can produce professional results by following a step-by-step plan. The secret is to start the project with complete preparation, making sure that all the necessary supplies and equipment are available.

To guarantee that the partitions precisely fit within the allotted space, the first steps entail meticulous measuring and planning. Building the frame—which acts as the foundation for the expanded clay concrete blocks—comes next after the layout is finalized. For the partition to be stable, the frame must be straight and stable.

A smooth and uniform finish can be achieved by keeping consistent spacing and alignment as you start to place the expanded clay concrete blocks. The blocks will adhere well and hold up over time if the proper mortar mixture and application are used. Paying close attention to details now can help avoid problems later on, like shifting or cracking.

Applying paint or plaster as finishing touches can improve the partitions’ appearance and help them blend in perfectly with the surrounding decor. To guarantee durability, it’s critical to give all materials enough time to dry. Expanded clay concrete partitions can enhance any area’s aesthetic appeal and practicality with time and careful installation.

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