Mini production of aerated concrete blocks: production line

Because of their exceptional insulation qualities and lightweight design, aerated concrete blocks are becoming more and more common in the construction industry. By adding air bubbles to the concrete mixture, these blocks are created, producing a material that is both sturdy and manageable. Mini production lines have grown in number as a result of the increased demand for aerated concrete blocks, which has made it simpler for small-scale businesses to manufacture these blocks locally.

There are several essential steps involved in setting up a small production line for aerated concrete blocks. The raw materials, which include sand, cement, lime, and a foaming agent, are prepared first in the process. To make a slurry, these ingredients are combined in exact amounts. After that, this mixture is poured into molds, where the chemical reactions inside cause it to rise and set.

The blocks are taken out of the molds and sliced to the appropriate size after they have solidified. In order to guarantee consistency and user-friendliness in building projects, this step is essential. After that, the blocks are cured—usually in an autoclave—where they are heated to a high pressure and strengthened to a greater degree of durability. The blocks are guaranteed to be prepared for use in a range of construction applications by this curing process.

Compared to larger industrial setups, mini production lines are advantageous because they require less space and money. They make it easier for local producers and small enterprises to enter the market and satisfy the rising demand for aerated concrete blocks. High-quality blocks that satisfy industry standards can be produced by these small production lines if the proper tools and procedures are in place.

The simplicity and efficiency of mini production lines make them an attractive option for entrepreneurs and small construction firms. By producing aerated concrete blocks locally, these businesses can reduce transportation costs and contribute to more sustainable building practices. Whether you are looking to start a new venture or expand your existing operations, mini production lines for aerated concrete blocks offer a practical and profitable solution.

Briefly about the types of production and organization of mini-business

It is worthwhile to begin by taking into account the primary production forms and phases of a business idea’s initial implementation. It is just essential to consider every option, even when producing goods at home to use in your own construction project.

Which technology is better to give preference to, comparison of finished products

One of two primary technologies can be used to produce aerated concrete. More specifically, their methods of product hardening differ from one another. which ultimately influences the outcome. This specifically relates to the primary set of properties of the material as well as the costs associated with the manufacturing process.

Thus, aerated concrete can be autoclaved or non-autoclaved, depending on the hardening technique.

• Autoclaved products, or aerated concrete of synthetic hardening, achieve technical strength by processing them in special equipment – an autoclave, through exposure to high pressure and temperature.
• Non-autoclaved aerated concrete, or hydration-hardening aerated concrete, achieves its grade strength naturally. Sometimes it can be heated to a low temperature in order to speed up the process.

Before deciding which production method is best, let’s look at some additional differences between these kinds of products. Use the table, please.

Calculation of the 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.

Name of the indicator, characteristics	Comparison of products
Thermal conductivity and density ratio of products	The thermal conductivity coefficient of both products is high. However, if we compare it with the density of the material, then autoclaved aerated concrete is significantly ahead.

Be aware that the formation of tobermorite, which gives synthetic aerated concrete its unique strength, occurs in the products upon exposure to high temperatures and pressure.

You can see that autoclaved aerated concrete performs noticeably better than hydration-cured aerated concrete, its rival. However, it is important to keep in mind that organizing the production of an autoclave comes with much higher costs when formulating a business idea and plan. Small-scale production carries a very high risk of bankruptcy because the costs could take too long to pay off. An autoclave-equipped production line for aerated concrete blocks is highly costly. The standard equipment for both production technologies will be discussed below, along with a price category comparison.

Kindly take note! Picking non-autoclaved gas blocks is still the better option when setting up a mini-plant. There are currently numerous approaches to raising the caliber of these goods. They consist of, for instance, the application of specialty additives.

It’s also important to note that hydration hardening blocks are less expensive, which implies that selling them will be simple with a strong marketing effort. The profitability of producing any material is directly impacted by the timing of its implementation.

Stages of organizing a business

As we’ve already established, aerated concrete mini-production can be set up for a number of uses, such as the one-time production of goods for your own building project or the release of materials for future product sales (business). In the latter scenario, knowledge of the phases involved in starting a business and the timeline for putting the plan into action is required. Let’s use a table to see what steps are involved in this process, what they are, and how long it will take to complete the process from the beginning to the line launch. Steps involved in setting up a mini-factory:

Stage name	Implementation period	Brief description
Preparation of documentation and business registration	From 3 days to several weeks	The stage includes the preparation of the Charter, registration of the organization, payment of fees, etc. The form of ownership can be chosen at your discretion. If there is one founder, then it can be a Private Enterprise, but if there are two or more, then the most popular form of ownership, in this case, is an LLC, that is, a Limited Liability Company.
Search and rent of the necessary premises	From 1 day	Depending on the scale, premises for a warehouse, the production itself and a legal address (office space) may be needed. Before concluding a lease agreement, it is worth carefully studying the real estate market, taking into account the favorable location, the cost per square meter and the convenience of payments.
Purchase of equipment and its adjustment.	1-3 weeks.	This stage should be approached with full responsibility. The market is rich in manufacturers offering a wide variety of lines for the production of products of various configurations. Their cost also varies. It is worth noting that too low a price should be alarming. Choose suppliers offering warranty service and a trial period for checking the equipment. The right choice, in this case, is almost half the success.
Purchase of raw materials for	Up to several weeks	An equally important stage. It is worth noting that the success of the business partly depends on the timeliness of delivery and the reliability of the supplier as a whole. The cost of raw materials on the market also varies, so it is worth carefully studying the price category in advance.
Hiring the required number of employees	About a week	To launch a mini-production, it will be enough to hire 3-4 people in the workshop, you will also need a chief accountant and an advertising specialist.
Launching the line, testing and releasing the first products.	Within a week.	First, adjust the equipment, then check.
Organizing advertising of products.	Constantly	It is necessary to draw up a commercial proposal, with the help of which you can offer your products to customers. The most cost-effective methods are: posting ads on specialized boards, distributing leaflets, using the media.
Selling products	Constantly	It will be necessary to prepare the appropriate documents. It is recommended to organize independent delivery, since this is the most convenient for the end consumer.

Overview of the production process

Now that we have talked about how to organize a business, let’s get straight to the technology. It is worthwhile to begin by carefully examining and researching the various types of equipment.

Necessary equipment and raw materials

• Conveyor;
• Stationary;
• Mini-plant.

• The conveyor type of equipment is almost completely automated, human participation in production is minimal and is reduced mainly to monitoring and controlling the machines.
• Its cost is extremely high, and the scale of production can reach 200 and 300 m3 per day. .
• The stationary version of the set of machines for the production of aerated concrete blocks is a small installation, the operation of which is partially automated. The production volume of the budget version of the set of machines is about 30-50 m3 per day.

A mini-installation is the most cost-effective choice. It can be produced at home as well.

Among the standard set are:

Mini-plants on wheels are part of the minimum set. For instance, this installation produces "GBS" 500 aerated concrete; it needs a small amount of space, and depending on the model, its daily output volume can reach 20–30 m3.

It is a movable unit with hoses for connecting the mixer and compressor. Although there are considerable labor costs associated with using it, these are offset by significant equipment purchase savings.

Purchasing used equipment can help you save even more money as it will come with a price reduction of at least 33%. The production process should be carried out by multiple persons as this will greatly expedite the work’s advancement. A brief word on the raw materials now.

These ingredients are needed to make aerated concrete:

• Cement grade not lower than 400;
• Clean water;
• Aluminum powder, which acts as a blowing agent;
• Quark lime;
• Quartz sand;
• Specialized additives in the form of fiberglass, polymer fiber, which improve the reinforcing properties. Calcium chloride accelerates hardening, and microsilica improves the performance of products.

Step-by-step work flow

The work order for a small aerated concrete plant would resemble this:

1. First, the components are dosed and loaded into the mixer. If there is no component dispenser, weighing is done manually using scales.
2. The mixture is made, or rather, mixed.
3. The last of all components is the gasifier.
4. The solution is poured into molds, in which, as a result of the chemical reaction of aluminum powder and quicklime, a gas formation process occurs, resulting in swelling of the solution.

Due to the large volume increase of the mixture during gas formation, the molds are not completely filled.

1. After completion of the above process, adjustments are made. Excess mixture is removed.
2. The products are kept in the molds for some time for their partial hardening;
3. Then you can strip the formwork.
4. Then the blocks are stored. They will reach the brand strength, in accordance with GOST, after 28 days. Only after this period of time, the use of the material in construction is allowed.
5. If a single form is used to form a block array, the product is cut using a cutting complex to the required sizes.

The following are the main disadvantages of this manufacturing method:

• In the absence of a component dispenser, the proportions of the raw materials can be violated. In this case, the properties of the material can be changed, and not always for the better.
• Time costs are colossal.
• Labor costs are also very high.
• A certain amount of material can be spent on unsuccessful products due to almost completely manual production.
• Lack of full control in artisanal or home production.

You can learn more about the steps involved in producing a product at home or in a small plant by watching the video in this article, "Mini aerated concrete production unit: operating procedure."

Economic feasibility of production

It is now worthwhile to examine the potential profitability of a small-scale production of aerated concrete products. Think about making use of the table.

Profitability of production for a mini-aerated concrete block production line:

Name	Cost per month, rubles.
Wages of workers, taking into account the number of 4 people	150,000
Cost of raw materials (1 m3 of block)	1800
Cost of raw materials taking into account the production of 400 m3 per month	720,000
Rent of premises, per month	100,000
Advertising costs, per month	10,000
Utility payments	150,000
Business expenses	50,000
Purchase of equipment, budget option	400000
Income
Sale of all products manufactured in a month, the cost of 1 m3 is 3500 rubles	1,400,000
Total monthly income, minus all expenses, except for equipment	220,000

On the optimistic side, the payback period is estimated to be two months. In any event, the organization will have enough revenue in 4–5 months, even at a reduced rate, to cover the expenses.

Step	Description
1	Prepare raw materials (cement, lime, sand, water)
2	Mix materials to form a slurry
3	Add aluminum powder to create bubbles
4	Pour slurry into molds
5	Let the mixture rise and solidify
6	Cut the solidified mixture into blocks
7	Cure the blocks in an autoclave
8	Cool and store the finished blocks

Meeting the rising demand for this adaptable building material may be accomplished in a clever and effective way by establishing a small production line for aerated concrete blocks. You can create high-quality blocks with consistent properties that are appropriate for a range of construction projects by starting a small-scale operation. A mini production line’s flexibility lets you modify the size of your business to suit the demands of the market.

The capacity to maintain tighter quality control is one of mini production’s major benefits. More attention to detail is possible with smaller production lines, producing blocks with exact dimensions and ideal performance attributes. This focus on detail can improve your products’ standing in the marketplace, resulting in happier customers and more referral business.

Furthermore, compared to larger setups, the initial investment for a mini production line is typically lower. Because of this, it’s a desirable choice for small companies and entrepreneurs who want to get into the building materials market without having to spend a lot of money. Furthermore, the equipment’s small size makes maintenance and troubleshooting simpler and faster, resulting in less downtime.

Smaller-scale aerated concrete block production may be more environmentally friendly. When compared to conventional concrete, the production process for these blocks usually uses less energy and emits fewer emissions. Greener building practices can be supported by further reducing your environmental impact through efficient production line optimization.

In conclusion, a small-scale aerated concrete block production line has many advantages, including environmental sustainability, cost savings, and quality control. By satisfying the demand for premium, environmentally friendly building materials, this strategy can offer a strong basis for a prosperous business in the construction sector. Considering that market trends are still in favor of sustainable construction solutions, forward-thinking business owners might find it wise to strategically invest in a small production line.

A compact production line for aerated concrete blocks can be set up to provide sturdy, lightweight building materials at a reasonable price. A few essential steps in this process are combining the raw ingredients, adding a foaming agent, pouring the mixture into molds, and curing the blocks to give them the proper density and strength. Small-scale producers can meet local demand for premium building blocks, cut transportation costs, and support sustainable building practices by establishing a condensed and efficient production line.

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