A growing number of people are using expanded clay concrete blocks as building materials because of their special blend of strength and light weight. Because expanded clay aggregates are used in their construction, these blocks have exceptional soundproofing and thermal insulation qualities. Due to its versatility, the material can be used for both residential and commercial construction projects.
The process of producing expanded clay concrete blocks entails multiple stages, starting with the careful selection of superior raw materials. Clay pellets are heated in a rotary kiln to the point where they expand and form tiny, porous aggregates, which is how expanded clay is made. Then, to make a concrete mixture that can be formed into blocks, these aggregates are combined with cement, sand, and water.
The environmentally friendly nature of expanded clay concrete blocks is one of their main advantages. The production process produces very little waste, and the blocks themselves offer superior insulation, which helps buildings use less energy. Furthermore, because they are lightweight, they lessen the overall load on building structures, which could result in construction cost savings.
To sum up, expanded clay concrete blocks are very beneficial for contemporary building. Because of their insulating qualities, durability, and light weight, they are a popular option for builders who want to increase the sustainability and efficiency of their projects. Expanded clay concrete blocks are expected to be a major component of building in the future due to the growing demand for eco-friendly building materials.
Feature | Description |
Material Composition | Expanded clay, cement, sand, and water are mixed to create lightweight blocks with good insulation properties. |
Production Process | Raw materials are mixed, shaped into molds, and cured to achieve the desired strength and durability. |
Lightweight | The use of expanded clay makes the blocks lighter than traditional concrete, easing handling and transport. |
Insulation | These blocks offer better thermal insulation, reducing energy costs in buildings. |
Durability | The blocks are strong and resistant to weather, making them suitable for various construction projects. |
- The concept of expanded clay concrete
- Main properties and composition of the material
- Classification of block products, choosing the optimal type of block for construction
- Strengths and weaknesses of buildings erected from expanded clay concrete blocks
- Step-by-step analysis of the production process
- Equipment and raw materials
- Manufacturing technology
- Brief analysis of the profitability of the issue
- Video on the topic
- Production of expanded clay concrete blocks
- production of expanded clay concrete blocks
- Production of expanded clay concrete blocks – "Teplostroy". Cheboksary
- Plant Building materials ChNP – expanded clay concrete blocks
- Production of expanded clay concrete blocks.Novocheboksarsk.
- Production of expanded clay concrete blocks
- Production of expanded clay concrete blocks at the Stroypostavka plant, g. Novocheboksarsk
The concept of expanded clay concrete
It will be important that you become acquainted with the content first. Think about the characteristics it possesses, the variables that may affect these characteristics, and most significantly, the kinds of products you ought to be mindful of when organizing the building of a specific structure.
Main properties and composition of the material
Expanded clay serves as the primary filler in the expanded clay concrete mixture. It can have varying fractions, which has an immediate impact on the outcome. Apart from that, the mixture consists of cement, sand, water, and other additives that can enhance the quality of the mixture and its subsequent products.
Additionally, sand, crushed stone, algoporite, pumice or slag gravel, and sand can be used as filler.
The products are lighter and have a lower thermal conductivity coefficient thanks to expanded clay. In turn, cement provides strength.
Let’s examine the qualities of expanded clay concrete blocks and determine whether this material is a good fit for your structure.
- The ability to retain heat in expanded clay concrete blocks is quite competitive, especially if you compare this coefficient with the density of the material. The numerical value is in the range from 0.14 to 0.45. This is significantly more than that of cellular concrete, but it is worth noting that the density of the latter is also lower.
- The number of frost resistance cycles can reach 200. This is an enviable indicator for almost all wall materials.
- Density varies between 400 and 2000 kg/m3.
Kindly take note! Only expanded clay concrete can achieve such a density indicator, making it a member of the lightweight concrete class. The construction of basements and foundations is another instance where it is utilized, defying the general consensus.
- Shrinkage. Expanded clay concrete is completely unaffected by shrinkage – and this is a significant plus. As a result, the walls are not subject to deformation, the appearance of cracks in this regard is excluded.
- Expanded clay concrete is hygroscopic, but the indicator of 18% is relatively small. Products need protection from moisture.
- The wall thickness for the average region of Russia should be at least 500 mm, subject to subsequent insulation. It"s not that much.
Classification of block products, choosing the optimal type of block for construction
Let’s now discuss how products are classified and attempt to determine which option is best for production.
Not every product listed below can be prepared at home. Some require expensive equipment for production, which will make small release unprofitable.
Depending on their goal, an explorer may be:
- Walls used for the construction of walls;
- Regulations used in the installation of partitions;
- Ventilation, characterized by the presence of special holes for the wiring of engineering communications;
- Foundation, with maximum strength and density. They are large -format products, they can produce in the form of hollow and full -bodied blocks;
- Precast monolithic floor blocks.
External characteristics categorize blocks into two groups: facing and ordinary.
The latter are used to install partitions and walls and need to be finished afterwards. Facing products don’t require additional finishing. There may be one facing side or two.
The presence of hollow and solid products was determined by the block’s potential structure. The first choice is less robust and weighs less. possesses a low thermal conductivity coefficient.
Because solid blocks are denser and heavier, they can support much larger loads.
The blocks’ surface structure can be smooth, ribbed, polished, or chipped.
- The corners can be rounded, straight. Blocks can have a groove, a ridge, or have a smooth surface without any recesses or depressions.
- The average density indicator became the basis for the emergence of another classification, which simultaneously determines the scope of application of the material.
- Accordingly, blocks are divided into: structural and thermal insulation, thermal insulation and structural.
- The first type is characterized by a density of 500-900 kg/m3. Popular among private owners of buildings. Used in the construction of partitions and walls. Houses can reach a height of 2-3 floors.
- Thermal insulation products are not capable of resisting loads. Used in the insulation of buildings as a thermal insulation material.
- Structural expanded clay concrete is the strongest and densest. However, in contrast to this, its thermal conductivity coefficient also increases significantly, which necessitates additional insulation.
Speaking of production methods, or more specifically, hardening methods, the expanded clay concrete block can be strengthened by processing it in an autoclave (autoclave hardening method) or by leaving it in the natural environment (non-autoclave method).
These goods will not be the same as one another. The autoclave will be less delicate and more robust. Its performance characteristics are higher and its geometry is generally better. You can only make non-autoclaved hardening products at home.
Strengths and weaknesses of buildings erected from expanded clay concrete blocks
Before we proceed with the production process, let’s examine the advantages and disadvantages of expanded clay concrete blocks.
Let’s begin with the material’s benefits:
- The material is environmentally friendly, does not contain harmful and hazardous substances.
- Expanded clay concrete block has a low weight, which reduces the load on the foundation of the building.
- Large dimensions can increase the speed of construction of the building.
- Low price.
- Possibility of DIY production.
- High strength, density and frost resistance.
- Durability of the material.
- Wide scope of application.
- Variability of sizes and choice of manufacturers.
- Vapor permeability and sound insulation.
- Low thermal conductivity.
- No tendency to shrinkage and deformation.
- Expanded clay concrete is not prone to biological influences.
- Fixation of almost any hardware, ease of fastening objects to the wall.
- Good adhesion with finishing materials.
- Variability of interior decoration and facade cladding.
Additionally, there are drawbacks.
The following are the principal ones:
- Fragility of products;
- Difficulty in processing;
- Hygroscopicity;
- Prevalence of handicraft production.
A common building material, expanded clay concrete blocks are renowned for their durability, light weight, and thermal insulation. Expanded clay aggregates are combined with cement and water during the production process to create a robust and eco-friendly material. These blocks are perfect for both residential and commercial construction because they provide good heat and sound insulation. Because they are lightweight, there is less strain on foundations, which can result in cheaper construction. Builders can efficiently employ expanded clay concrete blocks in a variety of construction projects by being aware of their special qualities and production method.
Step-by-step analysis of the production process
Now that the characteristics of the material have been determined, it is time to start thinking about the stages of production. It is worthwhile to begin with a summary of the equipment and raw materials that are required.
Equipment and raw materials
When it comes to manufacturing blocks in a factory, there are various kinds of equipment that can be bought and used:
- Conveyor type. It is characterized by maximum automation and large volumes of daily production. The cost of such a line is quite high, but the payback period, as a rule, does not take more than 12 months from the date of launch.
- Stationary line. Characterized by a more budgetary cost. Human participation is necessary not only as an operator. Completeness can be selected independently.
A vibrating press, molds, and concrete mixer are needed to make expanded clay concrete blocks at home.
- It is also possible to use a mini-installation. It is capable of producing up to 25 m3 of products per day. This depends on the model and, in turn, on the power, cost and manufacturer.
- The equipment can be built independently in order to save money. It is quite possible to make a machine for making expanded clay concrete blocks with your own hands. To do this, you will need instructions and a certain set of necessary parts.
- Now a little about the raw materials. As already mentioned, the composition of expanded clay concrete mixture includes cement, sand, water and filler. The most popular filler is expanded clay.
The future type of concrete is determined by the composition’s structure.
This means that it is separated into:
- Large-porous;
- Coarse-grained;
- Moderately dense;
- Dense;
- Fine-grained;
- With intergranular porosity.
The future density and strength of the composition are determined by the cement content relative to the total mass.
Manufacturing technology
The process of creating expanded clay concrete blocks by hand requires the solution to be self-prepared. First, let’s do this.
It is important to keep in mind when combining the ingredients that the ratios used to create expanded clay concrete blocks are merely suggestions rather than exact measurements. As a result, you must be ready for the possibility that your initial attempt at a flawlessly excellent block may not work out.
Blend the mixture in the subsequent sequence:
- First, pour water into the concrete mixer in an amount of approximately one part in relation to the total composition.
- Expanded clay gets there second, its amount is about 6 parts.
- Next, pour sand – three parts.
- Last, add cement – one part.
Counseling! Pick the raw materials with care. Both the cement grade and the expiration date must not be lower than 400. By using premium materials, you can partially ensure success.
There are steps involved in creating your own expanded clay concrete blocks.
What makes them fundamentally different is this:
- The finished mixture is formed and placed on a vibrating press. Through vibration, the solution is compacted, which significantly increases the strength characteristics of future products.
- The solution falls into the molds, the excess is carefully removed.
- Subsequently, the products should harden a little for about a few days.
- The next stage will be stripping.
- The blocks reach technical maturity after 28 days.
Similar principles apply to factory production, albeit with a higher degree of automation.
The products are processed in the autoclave if one is available at the end. You are not required to wait 28 days in this instance. Achieving the grade strength takes 12–14 hours.
The following are the benefits of factory-made blocks over handmade goods:
- As a rule, they are more durable;
- Composition and quality are controlled in accordance with GOST;
- Blocks have better geometry;
- Self-production takes a lot of time and delays construction.
- The durability of autoclaved products, as well as their performance characteristics, is higher.
The characteristics of this material are explained in the video review of expanded clay concrete blocks found in this article.
Brief analysis of the profitability of the issue
Regretfully, there is no way to compute a universal business plan because the profitability of production is contingent upon numerous factors, chief among them being:
- Cost of investment;
- Region of doing business, purchasing power in it;
- Cost of raw materials;
- Household expenses, quantity of defects and much more.
Of course, the economic feasibility can be roughly calculated. Assuming that a cube of expanded clay concrete block costs 2,300 rubles, let’s apply statistics.
- The equipment will cost, for factory production, 5,000,000 (budget version of the conveyor line).
- The average market value upon sale is 3,500 rubles per m3 of products.
- Let us assume that the daily production volume is 50 m3. In this case, the monthly one, with daily work, is 1500 m3.
- Income from the sale of all products will amount to 5,250,000.
- Net income: 2300*1500=3450000. 5250000-3450000=1800000
- Payback: 5000000\1800000=2.7 months. This, of course, is an extremely optimistic scenario, but still real.
- In the case of home production for your own use, the calculations look even simpler.
- Let"s assume that we need 150m3 of products.
- Cost – 2500, market value – 3500 rubles per m3.
- The cost of the equipment is about 60,000.
We calculate: 1000*150 = 150000; 3500 – 2500 = 1000.
15000-60000 = 90000 is what we stand to gain.
Expanded clay concrete blocks are a novel and adaptable building material that has several advantages for contemporary architecture. These blocks have a reputation for being incredibly durable, lightweight, and having good thermal insulation. They offer a cost-effective and environmentally friendly alternative for construction projects that call for sturdy, energy-efficient materials by combining expanded clay aggregates.
Cement, water, and expanded clay aggregates are combined to produce expanded clay concrete blocks. After molding this mixture into blocks, it is cured to give it the necessary strength and durability. Expanded clay aggregates are a great option for energy-efficient building because they improve the insulating qualities of the blocks while also lowering their weight. Furthermore, the aggregates’ porosity aids in the block’s capacity to control interior temperature and lessen sound transmission.
In general, architects and builders can find expanded clay concrete blocks to be a useful and environmentally friendly alternative. Their special blend of durability, thermal insulation, and lightweight construction make them appropriate for a variety of uses, including both residential and commercial buildings. For those aiming to strike a balance between performance, sustainability, and affordability in their construction projects, expanded clay concrete blocks offer a great option as the market for eco-friendly building materials keeps expanding.