Because of its exceptional insulating qualities and lightweight design, foam concrete is growing in popularity in the construction sector. Knowing how to make foam concrete can help you as a builder, developer, or do-it-yourselfer by providing new options for your projects. Even if you’re unfamiliar with the subject, this guide will walk you through the entire process, making it simple to understand.
We’ll go over everything in the upcoming sections, including the necessary ingredients and methods for mixing and pouring. You will discover what tools you require and how to make sure the mix turns out well. You can save time and money by making foam concrete that is robust, long-lasting, and effective with the correct knowledge and abilities.
We’ll clearly explain each step and offer advice along the way. You’ll be well-prepared to tackle your own foam concrete projects with assurance after reading this guide. Let’s delve right in and discover the fascinating realm of foam concrete production!
- Independent production of foam concrete blocks
- Brief characteristics and advantages of making foam concrete at home
- Calculation of the number of foam blocks
- Materials required for production
- Necessary equipment
- The main stages of production and technology
- Approximate cost calculation
- Production of foam concrete products in factory conditions: manufacturing features and profitability
- Equipment selection
- Types of production and technology
- Profitability of manufacturing foam blocks in a mini-plant: calculating the main costs and profits
- Physical and mechanical tests of foam concrete
- Video on the topic
- How to make foam concrete
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- Production of foam blocks, polystyrene foam blocks!
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- Production of high-quality FOAM BLOCK / revealing secrets
- Recipe for foam concrete of various densities
Independent production of foam concrete blocks
Many people believe that the process of producing building materials must only be done in factories and is impossibly large-scale. Few people are aware, though, that organizing product production on your building site can be a simple process. Let’s examine each step of the process in detail as well as the benefits of using handcrafted materials.
Brief characteristics and advantages of making foam concrete at home
The use of foam concrete for wall construction is very popular among prospective homeowners.
This is because of the features and attributes of foam concrete blocks, which consist of:
- Low thermal conductivity and, as a result, savings on insulation and heating of the building;
- Compressive strength
- Vapor permeability level. Thanks to this property, a favorable microclimate is established in the room;
- Low weight and, accordingly, low load on the foundation;
- Economic component. The material is relatively inexpensive, and construction from it does not require large investments.
- Foam concrete is an environmentally friendly material, and, importantly, safe, is included in the list of non-combustible materials;
- Installation speed. Foam concrete is easy to handle, almost anyone can handle the installation;
- Possibility of any subsequent finishing. Anything can be applied to walls built from foam concrete: decorative plaster, siding, panels, etc.;
- High sound insulation rate. The room will be protected from extraneous sounds, providing maximum comfort to those staying.
The issue of trying to make blocks yourself may come up a lot when planning the construction of a large house. Regardless of the potential savings, let’s weigh the benefits and drawbacks of this process and determine whether it is worthwhile to purchase pre-made blocks.
Calculation of the number of foam blocks
Selection of block size, LxHxD | |
Total length of walls, meters | |
Average height of walls, meters | |
Total area of window and door openings, m2 | |
Calculate |
m 3PC.m 3PC.
Advantages | Flaws |
Construction budget reduction. Blocks made with your own hands will cost much less, the price will drop to 30%. | Making foam concrete with your own hands is a rather labor-intensive process, it is necessary to carefully study the technology and spend a lot of time. Significant increase in construction time due to the time spent on independent production. |
The ability to independently control compliance with technologies and proportions | Significant investments in the purchase of equipment and raw materials. This disadvantage, from an economic point of view, can be turned into a plus: build the equipment with your own hands. |
Independent production allows you to choose the desired size, shape and strength of the foam concrete block. | Possible violations of technology due to inexperience |
Also, the disadvantages include the production of a certain part of defective goods during testing or equipment adjustment.
- It is quite difficult to correlate the proportions of foam concrete production;
- Experiments regarding the strength gain of a foam concrete block can negatively affect its quality;
- An increased amount of foaming agent in the solution can lead to a decrease in the strength indicator;
Although there are strong arguments against production’s shortcomings, most developers prefer independent work because it is more practical both financially and technically. One important factor is the desire to reduce construction costs without sacrificing quality.
Materials required for production
Like any building material, foam concrete blocks need to be produced with investment. The following raw materials must be kept on hand in adequate supply: hardener, foaming agent, water, sand, and cement.
These elements of upcoming blocks have to fulfill specific criteria:
- Cement grade M400 or higher is used;
- The foaming agent must be of good quality, with an acceptable shelf life;
- The sand is purchased purified.
Cement is the most expensive material out of all of them; it accounts for roughly 75% of the raw materials needed.
Nevertheless, purchasing a foaming agent is not essential. It’s something you can make on your own. You’ll need the following items for this: caustic soda, wood glue, or caustic soda and rosin.
Kindly take note! Manufacturing a foaming agent from scratch is a labor-intensive and time-consuming process. As a result, its use will be justified for planned home production in small volumes.
There are various phases to preparation:
- Dry glue is poured with water in a ratio of 1:10 and left for a day. After this time, the adhesive solution is heated to a temperature of 60 degrees and. Stir until a homogeneous consistency is formed.
- Next, caustic soda should be boiled for about several hours, adding rosin. This composition is mixed with glue at a temperature of 60 degrees in the ratio: 1 portion – rosin soap, 6 portions of glue.
The concoction is prepared! It can now be directed towards the foam generator.
Counseling! You must pour the resulting foam into a bucket and turn it over to assess its density and quality. There will still be high-density foam inside.
Necessary equipment
The following tools are required, per technology, in order to produce foam concrete blocks:
- Foam generator. Its main components: nozzle, diffuser, suction pipe, displacement chamber, mating flange, body part. The purchase of this module is the most consumable.
- Concrete mixer. It is used in the production of the block at home, in factories they use a mixer.
- Molds for mortar
- Compressor unit for the production of foam concrete
- Pumping equipment
Since this equipment is fairly pricey, you might try producing it at home to save even more money.
You can use metal or plywood sheets to make the molds. The procedure calls for extra care because they have to be geometrically even. Polyethylene can be used as insulation for the mold, which will stop the solution from leaking.
The main stages of production and technology
Depending on the equipment used, foam concrete blocks can be produced in a variety of ways. Not all of them are appropriate, though, when it comes to creating foam concrete by hand.
Dry mineralization of the composition and release using barosmixers and specialty mixers mostly take place in factory settings. The simplest classical method, which involves combining the solution with a foaming agent, can be produced at home. We’ll give it some thought.
Foam concrete block manufacturing is a multi-stage process. First, water is added to a concrete mixer along with cement and sand.
Following that, add a pre-made foaming agent at a rate of roughly 500 liters of foam for every 1 m3 of foam blocks. A unique nozzle on a lot of contemporary foam generators allows foam to be pumped straight into the concrete mixer.
Kindly take note! The amount of foam added determines the future block’s density. Don’t go overboard, though, as using too much of this raw material will have a detrimental effect on the outcome. Maybe the block just isn’t drying.
The mixture can be transferred to the molds where the blocks will solidify after all the ingredients have been well combined. After that, the foam block is taken out and given a full day to dry.
Approximate cost calculation
Let’s look at the costs that will need to be paid for the process of producing blocks on our own using a table, and then compare those costs to those of buying pre-made goods. Let’s assume for the sake of simplicity that the developer requires 100 m3 of foam block for construction.
Table 2: Cost price calculation for 600 kg/m3 density foam concrete blocks:
Name | quantity | Unit cost | amount |
Cement grade 400 | 33 t | 5000 rub/t | 165000 |
Sand | 21 t | 400 rub/t | 8400 |
Foaming agent | 110 kg | 85 rub/kg | 9350 |
Water | 22000 l | 25 rub/m3 | 550 |
Entire expense: 183 300.
Table 3: Cost price calculation for 800 kg/m3 density foam concrete blocks:
Name | quantity | Unit cost | amount |
Cement grade 400 | 40 t | 5000 rub/t | 200000 |
Sand | 34 t | 400 rub/t | 13600 |
Foaming agent | 110 kg | 85 rub/kg | 9350 |
Water | 26000 l | 25 rub/m3 | 650 |
Cost in total: $223 600.
A 1 m3 foam block with a density of 600 kg/m3 costs approximately 3000. Consequently, the cost of 100 m3 is 300 000. Savings: $126,700.
The cost of one m3 of foam block with a density of 800 kg/m3 is slightly higher, at roughly 3400 rub. The cost of 100 m3 is 340 000. As a result, 116 400 will be saved.
Kindly take note! The figures are estimated. The manufacturer and the area affect the cost. This holds true for materials as well as foam blocks.
Nevertheless, equipment costs are not factored into these computations. The cost, if you make it yourself, will be between 50,000 and 70,000 rubles. If purchased pre-made, it costs roughly 100,000.
Temporary rental is another option; this is especially important if the installation is no longer needed. Costs will also be kept to a minimum.
Production of foam concrete products in factory conditions: manufacturing features and profitability
Because foam concrete block production is a lucrative enterprise, interested businessmen as well as cost-conscious site owners are drawn to the idea of producing these blocks.
Equipment selection
It will be expensive to set up a business for the production of foam concrete. They are mainly related to purchasing the required raw materials, renting out space, and buying equipment.
- The minimum set of equipment includes: mixer, foam generator, block molds, compressor, foam concrete pump.
- The best option would be to purchase an automated unit. It almost completely eliminates human intervention. The main advantages of using a comprehensive set are speed and high quality. The price, of course, is much higher, but the result is appropriate.
- The choice of a supplier should be approached with special responsibility. Cooperation with companies that have a positive reputation in the market for the supply of industrial equipment can radically affect the future success of the organization.
The organization requires more technical equipment and different inventory to guarantee complete compliance with the technological process and storage conditions.
It includes:
- A warehouse suitable for storing finished blocks;
- Pallets that meet the requirements of GOST
- Equipment for heat treatment of foam concrete products;
- Automated bin for cement and sand, capable of pouring material in portions;
- Conveyor for sand supply (belt);
- A place for storing sand, in which a certain temperature and humidity level must be maintained.
Types of production and technology
The primary techniques for producing foam concrete in a factory setting are as follows:
- Barotechnology allows feeding all the necessary components into the mixer under pressure. The components are mixed in the required dosage and the finished solution is fed at the outlet, which is sent to the molds. In this case, the use of a foam generator is not required.
- Porization technology allows the process to be carried out directly on the construction site, since this method uses mobile mobile equipment. Foam is produced in a vaporizer, which feeds it through a pipeline, and the finished mixture enters the molds through a hose.
- The classic technology, which was already mentioned above, is also used in production, but the process is more automated. This is the most popular method of all.
Let’s examine how the entire foam concrete production cycle works with more sophisticated machinery rather than handcrafted components. In this instance, machine operation is paramount and essentially does not necessitate human involvement.
A brief set of guidelines for using the automated line:
- The operator starts the process of dosing the material (cement, sand and water);
- The auger for feeding cement automatically turns on and feeds it into the appropriate compartment. Feeding is completed after the required amount is collected;
- Next, sand is fed by a belt conveyor, which is also fully automated by analogy with an auger;
- In parallel with these processes, a dose of water is collected and, when the required portion is collected, bulk materials are unloaded;
- Lastly, foam enters the unit.
- The finished mixture is poured into molds and dries.
- After the time required to gain optimal strength, the massif is stripped and then cut.
When foam concrete is produced on such a line, all specifications and quality indicators will be satisfied. This article’s video will walk readers through the general idea behind how such an installation works.
Profitability of manufacturing foam blocks in a mini-plant: calculating the main costs and profits
Working out the necessary expenses and potential earnings is one of the most crucial steps. You can use it to determine what kind of initial capital is needed. How much time will it take to repay? Which of the major expenses will be one-time and which will be ongoing.
Table 4: Financial Efficiency of the Organization’s Foam Concrete Production Activities: Income and Expense Calculation
Nature of expenses | Quantity | Unit cost | Amount |
Purchase of a complete set of equipment, including: |
- Mixer
- Compressor
- Molds for blocks
- foam generator
The table shows that the costs can be recovered in just one month. However, this is the most hopeful choice. Other organization needs and advertising expenses are not considered. Only the expenses that the organization cannot live without are displayed in the table.
Physical and mechanical tests of foam concrete
According to GOST 25485-89, tests of completed goods must be performed at any production facility. Appendices 3-5 stipulate that samples must be chosen in quantities ranging from three to twenty-one in order to conduct mechanical and physical testing on foam concrete. Testing is done on the shrinkage, elasticity, and resistance to frost.
GOST Cellular concrete contains explicit instructions on how these tests are to be carried out. technical circumstances.
As an example, let’s look at the phases of the control method using frost resistance:
- In accordance with this method, frost resistance is understood as the number of freezing and, accordingly, thawing cycles during which the strength decreases by no more than 15% and the weight of the block by no more than 5%.
- Tests are carried out after a certain time, sufficient for the foam concrete to achieve strength.
- Samples are frozen and defrosted in special chambers, and then the result is determined using modern technologies and formulas.
- All final indicators must comply with GOST, otherwise the manufacturing organization will not be able to certify its product.
Step | Description |
---|---|
1 | Gather materials: You"ll need cement, water, foam agent, and aggregates. |
2 | Mix the dry ingredients: Combine cement and aggregates thoroughly. |
3 | Create foam: Use a foam generator to produce a stable foam. |
4 | Combine foam and mix: Gently fold the foam into the dry mix until evenly distributed. |
5 | Pour the mixture: Transfer the foam concrete into molds or forms. |
6 | Allow to cure: Let the foam concrete set for at least 24 hours before removing molds. |
7 | Finish the surface: Smooth out any rough spots and ensure even surfaces. |
8 | Inspect quality: Check for any cracks or defects before using the concrete. |
Creating foam concrete can be a game-changer for developers and builders who want to cut expenses and increase productivity. You can make sure that your projects take advantage of foam concrete’s special qualities, like its exceptional insulation and lightweight nature, by adhering to the detailed process. Achieving consistent results is made easier with this guide, which lays out everything from mixing the right materials to pouring and curing.
Keep in mind that each step of the process requires careful attention to detail. Ensuring quality control throughout the entire process, from mixing to curing, can help you prevent problems and improve the overall functionality of your foam concrete structures. Stressing the proper ratios and methods will result in a long-lasting and environmentally friendly building material that satisfies contemporary building requirements.
When producing foam concrete, don’t be afraid to try new things and modify the techniques to fit your own requirements. Through experience and practice, you’ll discover methods to streamline your workflow and produce the greatest results for your projects. Accept the benefits that foam concrete provides and observe how it can revolutionize your building endeavors.
Lastly, exchanging insights and knowledge with other builders can stimulate creativity and enhance procedures in the sector. We can improve the application of foam concrete and broaden our understanding of this useful material by cooperating and sharing advice. So take advantage of foam concrete’s advantages and confidently tackle your next project!
This post will give developers and builders a clear, detailed tutorial on creating foam concrete, outlining its advantages, required materials, and procedure. By dissecting each step, we hope to increase accessibility to foam concrete and highlight its usefulness and effectiveness in building projects. This guide will assist you in producing high-quality foam concrete that satisfies your building needs, regardless of whether you’re new to the material or looking to improve your technique.