Polystyrene concrete production technology: an overview of the manufacturing process and economic profitability of product release

Expanded polystyrene concrete, sometimes referred to as polystyrene concrete, is a revolutionary material that is redefining the construction industry. This special kind of concrete is made by mixing regular cement with polystyrene beads, producing a lightweight, insulating substance that is becoming more and more well-liked for a variety of uses. Because of its qualities, it is a desirable choice for projects involving both residential and commercial spaces, providing advantages beyond merely providing structural stability.

A few simple but essential steps are involved in the creation of polystyrene concrete. The polystyrene beads are first combined with water, a cement-based binder, and occasionally extra additives to improve the performance of the mixture. The end product is a uniform mixture that, when dried, solidifies into a lightweight but robust substance. Significant construction flexibility is made possible by this process, particularly in locations where conventional concrete might be too expensive or heavy.

Polystyrene concrete is a strong argument in terms of economics. Because of its light weight, it is less expensive to handle and transport, and over a building’s lifetime, its insulating qualities can result in lower energy costs. Its quick setting times and simplicity of use can also expedite building projects, thereby reducing labor costs. Overall, polystyrene concrete can be a wise investment for many construction projects due to its financial advantages.

The increasing need for economical and environmentally friendly construction materials makes polystyrene concrete an appealing option. Builders and developers can make well-informed decisions that complement their budgets and project objectives by comprehending the product’s manufacturing process and economic benefits. This synopsis of the profitability and production technology of polystyrene concrete demonstrates why it’s gaining popularity as a material for contemporary construction.

Aspect	Description
What is Polystyrene Concrete?	Polystyrene concrete is a type of lightweight concrete that includes expanded polystyrene (EPS) beads. These beads replace some of the aggregate material, making the concrete lighter and insulating.
Manufacturing Process	The process involves mixing cement, water, and EPS beads. The mixture is then poured into molds and allowed to set. The EPS beads help reduce the weight of the concrete while still maintaining strength.
Advantages	Polystyrene concrete is known for its low weight, which can reduce transportation and structural costs. It also provides good thermal insulation and soundproofing.
Disadvantages	It may have lower compressive strength compared to traditional concrete and can be more expensive due to the cost of EPS beads.
Economic Profitability	While the initial cost of polystyrene concrete can be higher, its benefits in terms of reduced transport costs, lower structural demands, and energy savings can make it economically viable in the long run.

Briefly about polystyrene concrete: composition and properties of the material

Apart from organizational concerns, you must first acquaint yourself with the properties of the material and the makeup of the raw materials for a successful start of production. Yes, it would be foolish to create something you have no knowledge of.

Thus, one example of lightweight concrete is polystyrene concrete. It varies in that the composition contains different amounts of polystyrene and concrete crumbs in addition to specialty additives that enhance the properties of the mixture and the products made from it.

The percentage of polystyrene can vary; the main source of variation is the desired density indicator. The relationship is straightforward: a block’s weight and heat-saving ability increase with the amount of polystyrene it contains.

Now let’s discuss the key characteristics:

• Like other types of lightweight concrete, depending on the average density, polystyrene products can be used as a heat-insulating or structural material. This indicator can vary from 150 to 600 kg/m3.
• Thermal conductivity of dry material starts counting from a numerical value equal to 0.05. In this regard, polystyrene concrete can be said to be the leader. The maximum value does not exceed 0.145.

Naturally, the final structure built with polystyrene concrete will have a higher coefficient because it will be in an operationally humid state. There won’t be any big changes, though.

• Polystyrene concrete is characterized by a high grade of frost resistance – it can reach 200. This means that the products can withstand the effects of up to 200 cycles of periodic freezing and thawing.
• It is also worth noting that polystyrene concrete is an environmentally friendly material, it does not burn. However, it is not able to withstand high temperatures for a long time.
• The durability of the products leaves no doubt. Much depends on the manufacturer, operating conditions, composition of raw materials and technically correct finishing. However, if all standards are met, polystyrene concrete will last an extremely long time.

• The strength grade is directly dependent on the density. The minimum value established by GOST is B 0.35.

Specifications of concrete made of polystyrene:

Indicator name	Meaning
Thermal conductivity coefficient, W*mS	0.05-0.145
Average density, kg/m3	150-600
Strength grade, B	0.35-5
Frost resistance, cycles	25-200
Shrinkage	Up to 1 mm/m2
Water absorption	5-8%

Stages of the production process

Now that we are familiar with the subject, it is time to think about production technology. And we’ll get started with a list of the supplies and tools that we’ll need.

Necessary equipment and raw materials

Purchasing one of several line options is necessary for the production of polystyrene concrete blocks:

• Conveyor-type line – maximally automated. Involvement of labor is practically not required. Characterized by high cost and maximum return. Production volumes are usually large.

Good geometry and high performance are attributes of products manufactured on such equipment because of exact component dosing and strict adherence to technology.

• Stationary type line – a more budget option. However, the main disadvantages are the need to attract additional workers and a limited number of manufactured products, which cannot be as large as when using a conveyor.

One can select any level of completeness for such equipment. The availability of machines has an impact on the outcome, which should be considered.

• For the development of small businesses, or when making polystyrene concrete with your own hands, a mobile unit is perfect. The price for it is low, and the productivity can reach 30 m3 per day.

The following are the drawbacks of using the unit: you will have to weigh the proportions of raw materials yourself, which increases the likelihood of errors; you may overspend on components because of inexperience and partially manual production.

A set that includes a concrete mixer, raw materials, and product molds is the most basic and least expensive. A continuous supply of the mixture can only be guaranteed by investing in a foam generator if your daily production output exceeds 25–30 m3.

Regarding composition, the primary ingredients are polystyrene chips, cement, water, and sand, as was previously mentioned. Wood resin is frequently added to products.

There are only suggestions rather than a precise recipe. Thus, it is only beneficial to have an experienced technologist on the team when starting a business.

This is one of the reasons there can be big differences between products made by different manufacturers.

Description of technology

There are two primary methods for producing polystyrene concrete: semi-dry pressing or casting.

Certain steps must be implemented in order to use the technology for casting polystyrene concrete blocks.

Here’s how the instructions appear:

• First, ingredients are fed into the mixer in the required proportions;
• Mixing occurs;
• The finished solution is poured into molds, which are recommended to be pre-lubricated with a special compound. Diluted machine oil is also suitable;
• After a few days, you can dismantle the products. In winter, you will have to wait a little longer;
• The grade strength is achieved only after 28 days, before this period it is not recommended to use the blocks in construction.

The end result is low to medium density products. The degree of automation is the only significant difference between the primary work order in a factory and a home. In both situations, the same technology is used to produce polystyrene concrete blocks.

The final goods will differ from one another. Handcrafted blocks are likely to be less abrasive and even have some geometry violations. Additionally, creating a high-density block on your own is challenging.

As the products are not subject to any authority, it is impossible to precisely describe their features. Vibration pressing is the more advanced and effective second method.

Its main points are as follows:

1. The cement content in the solution is usually increased, and the water content is decreased. The mixture is very thick.
2. Using a vibration press, the products are brought to a semi-dry state.
3. The next step is processing the blocks in a drying cabinet.

The steps in the production process are covered in the video in this article, "Production of polystyrene concrete blocks: manufacturing technology."

Business formation and feasibility study

It is insufficient to merely familiarize yourself with production technology in order to initiate business organization. As we shall see in a moment, it is also essential to thoroughly research and evaluate each step of the registration and formation process.

Stages of organizing a business idea

Steps involved in setting up a company to produce polystyrene concrete and its byproducts:

Kindly take note! Before making a purchase, it is crucial to consider the cost differences between raw materials from various suppliers.

The sale of the goods will, of course, be the last phase.

Approximate calculation of profit

Without accounting for every detail, it is impossible to compute the profit with any degree of accuracy. What kind of money such a production can generate is only speculative.

Let us assume that the price of a single m3 of concrete block made of polystyrene is 2,200 rubles. A daily production volume of 200 m3 is achieved. There is a conveyor-type line that costs eight million rubles in use.

The products will be offered for 3,200 rubles per cubic meter. Based on the monthly sales of every product produced, we will make 19,200,000 and spend 13,200,000. Six million rubles will be made as profit.

You should also subtract the following from this sum:

• Employee salaries – 300,000;
• Contributions and taxes – 1,000,000;
• Rent – 500,000;
• Organization business expenses – 500,000;
• Advertising expenses – 500,000;
• Utility payments – 1,000,000.

There are still 2,200,000 left. In this instance, 8 million rubles worth of equipment will pay for itself in three to four months.

Expanded polystyrene (EPS) beads are mixed with conventional concrete to create polystyrene concrete, a novel building material that improves insulation and lowers weight. This article looks at the production of polystyrene concrete, showing each stage from mixing to curing, and analyzes the financial advantages of creating this novel material. We’ll demonstrate how polystyrene concrete not only offers better thermal efficiency and reduced structural load, but also presents an affordable option for today’s construction needs by comparing costs and performance with conventional concrete.

Advantages and disadvantages of polystyrene concrete that you should know

Given that the focus of this article is on the manufacturing of polystyrene concrete and building a profitable business using it, it is important to consider the material’s primary advantages and disadvantages.

Let’s begin with the benefits:

• Low thermal conductivity of the material and products made from it will save on insulation and heating. High heat retention capacity allows the use of polystyrene concrete as a material for thermal insulation.
• Good density and strength indicators. Using the products, it is possible to erect private low-rise buildings.
• High frost resistance grade.
• Ecological friendliness of the material, non-flammability.
• Affordable price for the consumer;
• Possibility of home production.
• Wide scope of application.
• Availability of the product with a facing side in the assortment.
• Soundproofing ability.
• Vapor permeability contributes to the establishment of a fairly favorable microclimate in the room.
• Ease of use.
• Speed ​​of construction is a significant plus. The products are characterized by considerable dimensions, which will directly affect the process.
• A large number of finishing options, both internal and external.

The following are the drawbacks:

• Low, but still, hygroscopicity of the material.
• Polystyrene concrete is prone to shrinkage.
• Problems may arise when trying to fix heavy elements to a wall made of polystyrene concrete. Specialized fasteners are required.
• The prevalence of artisanal, uncontrolled production.
• Fragility of products. Polystyrene concrete is afraid of mechanical impact.
• Low level of adhesion with finishing materials and, as a consequence, the need for additional costs.

Kindly take note! Certain drawbacks of polystyrene concrete can be totally avoided. For instance, by demanding a passport and quality certificate, you can guard against purchasing inferior goods. Technically sound finishing levels hygroscopicity, and fastening units can be planned ahead of time.

Combining the strength of conventional concrete with the lightweight qualities of polystyrene beads, polystyrene concrete presents an inventive method of building. These beads are mixed with cement and other ingredients during the production process to create an insulating and robust material. This combination not only improves a building’s thermal efficiency but also lightens the structure overall, making it easier to handle and move.

Polystyrene concrete turns out to be a wise decision in terms of cost. Because the material has a lower density than conventional concrete, its production costs are frequently lower. This may result in labor and material cost savings. Long-term financial gains can also result from its insulating qualities, which can lower energy costs for buildings’ heating and cooling systems.

All things considered, polystyrene concrete technology is a positive development for environmentally friendly building. It’s a desirable alternative for contemporary construction projects due to its effectiveness and affordability. Polystyrene concrete sticks out as a sensible and progressive solution as the building sector looks for new and creative ways to innovate while lowering its environmental effect.

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