The utilisation of cellular concrete blocks in construction is on the rise owing to their distinct characteristics and advantages. These blocks are a great option for many different building projects because they are lightweight, very insulating, and simple to work with. However, what distinguishes cellular concrete blocks from regular concrete? This article will examine the unique characteristics of these blocks and examine the technology utilized in their manufacturing.
The porosity of cellular concrete blocks is one of their most distinctive features. By adding air bubbles to the concrete mixture, this feature is made possible while maintaining the strength of the blocks and drastically lowering their weight. This reduces labor costs and on-site time because they are much easier to handle and transport. Better thermal and acoustic insulation is also provided by the air pockets inside the blocks, which results in quieter and more energy-efficient buildings.
A few crucial processes are involved in the production of cellular concrete blocks. To make a slurry, first combine cement, water, and a foaming agent. After that, this slurry is poured into molds, where the foaming agent causes it to set and expand. To obtain the required strength and durability, the blocks are cured under carefully monitored conditions after the initial setting is finished. In addition to guaranteeing consistent quality, this technique enables customization of block shapes and sizes.
Technological developments in production have enabled the production of cellular concrete blocks with exceptional accuracy and uniformity. Every block is guaranteed to meet stringent quality standards thanks to automated systems that manage the mixing, pouring, and curing procedures. By reducing waste and maximizing resource use, this technological sophistication not only improves the performance of the blocks but also helps to promote more sustainable building practices.
Cellular concrete blocks are emerging as a viable alternative in response to the growing demand for cost-effective and environmentally friendly building materials. Their exceptional insulating qualities, lightweight design, and adaptability to various applications render them appropriate for a diverse array of construction requirements. Better built environments for everyone can result from builders and architects making educated decisions based on an understanding of the features and production technology of these blocks.
Feature | Description |
Material | Made from cement, lime, sand, water, and aluminum powder |
Weight | Lightweight, easy to handle and transport |
Insulation | Excellent thermal and sound insulation properties |
Strength | Strong and durable, suitable for various construction needs |
Production | Involves mixing materials, pouring into molds, and curing in autoclaves |
Eco-friendly | Energy-efficient and environmentally friendly production process |
- What is cellular concrete
- Characteristics of the material: composition and properties
- Types of products
- Production of the material
- List of equipment
- Step-by-step process
- Overview of the range of cellular concrete of various brands and manufacturers
- Comparative analysis of cellular concrete
- Autoclaved and non-autoclaved cellular concrete
- Comparison of representatives of cellular concrete with each other
- Video on the topic
- Production of sawdust concrete blocks as a business idea
- Production of PORITEP gas silicate blocks
- Production of cellular concrete cellular concrete plant
- Production and technology of manufacturing gas silicate aerated concrete blocks
- Production of polystyrene concrete blocks
- Production of FBS concrete blocks in the "M-Constructor" metal mold
What is cellular concrete
The porous structure that distinguishes all cellular concretes from other lightweight concrete variants. These kinds of porosities can be obtained in a variety of ways, or more accurately, by changing the composition to some extent, depending on the particular kind of material. Let’s give it a closer look.
Characteristics of the material: composition and properties
Cement, sand, water, chemical additives, and an ingredient that promotes cell formation are the ingredients of all cellular concretes.
Let’s now familiarize ourselves with the recipe for each kind of representative:
- In most cases, cement acts as the main binder. As a rule, its grade should not be less than 400, otherwise the strength characteristics will suffer.
- In accordance with GOST for cellular concrete blocks, the following can also act as a binder: lime, ash, slag, a mixture of components from gypsum, slag and cement.
- Blocks made of cellular concrete can be produced using one or another siliceous component. These are: sand, ash and other secondary waste from industrial production.
- Now a little about pore formation. If foam concrete blocks are produced, then the cellular structure is achieved by adding a foaming agent to the composition.
- A cellular aerated concrete block has a slightly different recipe. Swelling of the mortar mixture occurs due to a chemical reaction between quicklime and a foaming agent. Gas-forming agent – aluminum powder.
- When producing foam concrete, manufacturers combine both technologies: foaming and gasification.
- If we talk about fiber-reinforced foam concrete, it differs in the addition of a reinforcing component to the composition, which can affect the strength characteristics of products. These are: plant, basalt, synthetic, glass, composite fibers or granules.
- Almost all manufacturers use a plasticizer in the production of products. It is added to the solution in order to increase its plasticity.
- Chemical components are individual. With their help, manufacturers are able to improve the properties of finished products. This concerns frost resistance, density, thermal conductivity and other qualities of products.
Now, let’s talk about the properties.
Table 1: Product characteristics of aerated concrete blocks:
For foam concrete, the minimum value is typically 0.05 W*mC. Aerated concrete, fiber foam concrete, and foam concrete take the next three spots in the ranking.
The materials are suitable for use in cold climate construction because of their high capacity to conserve heat.
There is only a 40 cm minimum wall thickness allowed.
Documentation for cellular concrete blocks: GOST 21520 89 establishes the minimal value requirement for materials used in exterior wall construction. There are twenty-five cycles.
Depending on the product’s type and the way it was hardened, cellular concrete may shrink.
However, aerated concrete can absorb up to 25% more moisture than regular concrete.
It is important to highlight a few more drawbacks of the products: cellular concrete is brittle and ripply. It is required to buy specialized hardware in order to fasten objects.
Types of products
Let’s start by talking about the classification, which is determined by a group of materials’ combined use and, consequently, density.
- Cellular concrete, the density of which is less than 400 kg/m3, is used mainly as thermal insulation products. Despite its short existence, foam aerated concrete occupies the first line of the rating in this regard.
It has the highest thermal efficiency, as noted. In theory, though, all products—regardless of kind—are actively utilized as insulation, and not just blocks. Developers are also big fans of aerated concrete and monolithic foam.
- Pay attention to low-rise block houses – most of them are built using structural and thermal insulation products, the density of which is slightly higher. At the same time, the thermal insulation qualities still remain high, and fall only with an increase in strength indicators. The density of this type of cellular concrete is within 500-900 kg / m3.
- You can erect a building of 3 or 4 floors using a structural type of material. It is the most durable of all the named.
- Separately, we can highlight the foam block, it can have an even higher density grade, reaching 1600 kg / m3. However, it has not received widespread distribution, and is produced in limited quantities to order. It is called structural-porous.
- With the help of wall blocks, of course, walls are erected;
- Partitions made of cellular concrete blocks are mounted using partition products;
- U-shaped blocks can be used when creating formwork, when installing openings and in some other cases.
- The range of foam blocks includes facing products, that is, having a facing side.
Products made of cellular concrete may exhibit some geometric irregularities. The GOST sets the requirements for them. The allowed values are displayed in the picture.
One of two methods—autoclave or non-autoclave—can be utilized to harden the material during block production. In the context of the technology, we will address this in greater detail. It is only important to note that this causes the products to differ from one another.
In the first instance, autoclaving gives them strength; in the second, nature provides it. Consequently, there is a distinction in traits.
As was previously mentioned, products come in a variety of sizes. The dimensions of cellular concrete blocks are displayed in the picture below.
Production of the material
Since getting to know the material went well, let’s go straight to the manufacturing process. And start by thinking about how diverse the machinery that can be employed in manufacturing is.
List of equipment
The choices for equipment configurations and manufacturers are countless. They are all different in a few key ways. However, the primary distinctions are primarily determined by capacity, volume of production per day, expense, and process automation level.
- Conveyor-type equipment lines – the most expensive. They require large areas. At the same time, the manufacturing process is fully automated, from dosing to transportation of finished products. As a result, labor costs are minimal, the release speed is high, and the quality of the products, as a rule, is one of the best.
- A more simplified option is stationary equipment. When using it, you can produce up to 100 m3 per day. It takes up less space, costs less. However, it requires the involvement of an additional number of employees, since some processes are carried out manually.
- Mini-factories and mini-installations are good for the development of small businesses. The output volume is small, but the investment is not so great.
- When producing with your own hands, you can get by with the presence of molds, a concrete mixer, and, in the case of making foam concrete, you will also need a foam generator. You can additionally save money by making the molds yourself. You will need sheet metal or plywood sheets. The instructions are quite simple, and you can find them on the Internet.
Step-by-step process
For all of its representatives, the technology used to create products from cellular concrete is the same.
Thus, the following are guidelines for producing goods using cellular concrete:
- First of all, component dispensers measure out raw materials in specified proportions. In automated production, this parameter is set by the machine operator.
- Next, all ingredients are fed to the mixer via a belt conveyor, where they are mixed until a homogeneous mass is formed. This procedure, as a rule, does not take more than 5-7 minutes.
- The next step is molding. The finished solution is poured into molds, which are filled halfway. This is necessary so that during the swelling process, the excess does not spill over the molds, since the solution will increase in volume by about twice.
- After completing the above process, you should wait a certain time, during which the block massif will harden.
- Then cutting is carried out – it is carried out using a cutting complex, which is included in the conveyor and some types of stationary equipment.
- Then the blocks are autoclaved or sent for natural drying.
- After processing in an autoclave, the blocks can be immediately used in construction.
- A non-autoclaved block gains strength within four weeks.
Foam concrete is made differently; first, the foam is made separately and then mixed with the other ingredients.
The process follows the same plan when making cellular concrete blocks at home. The majority of the stages involve manual labor, so the main differences are in labor intensity and time commitment.
The steps of factory and home production are depicted in the video included in this article.
Lightweight and adaptable, cellular concrete blocks are highly regarded for their superior insulating qualities and simplicity of use in construction. This article examines the special qualities of these blocks, including their remarkable fire resistance and strength-to-weight ratio. It also explores the manufacturing process, covering everything from the preparation of raw materials (such as cement and aluminum powder) to the curing techniques that give the blocks their unique polyhedron shape. Comprehending these attributes and the manufacturing methods of cellular concrete blocks underscores their increasing prevalence in eco-friendly and productive construction methodologies.
Overview of the range of cellular concrete of various brands and manufacturers
Table 2: Market overview of goods manufactured from cellular concrete
The company operates numerous branches throughout numerous Russian cities.
Comparative analysis of cellular concrete
Let’s now examine how cellular concrete stacks up against each other and against other widely used materials.
Autoclaved and non-autoclaved cellular concrete
We discovered that there are two types of cellular concrete blocks: hydration (non-autoclaved) and synthetic (autoclaved). The products have distinct qualities. Now let’s ascertain what they are.
- Autoclaved block is more durable in relation to lower density indicators;
- It is white, and non-autoclaved is gray;
- The latter is more fragile;
- Products of synthetic hardening can be manufactured exclusively in production conditions;
- Autoclaved cellular concrete is somewhat more expensive;
- When purchasing a non-autoclave, you should be extremely careful, since the risk of buying low-quality products is much higher, due to the presence of small handicraft industries that are completely uncontrolled.
- As it turned out, the autoclave has better geometry, which cannot but affect the heat-saving ability of the finished structure.
Non-autoclave products are not supported by these or a host of other factors. On the other hand, you can prioritize these products if the lowest price is your primary need.
Comparison of representatives of cellular concrete with each other
Table 1: Equivalency of the characteristics of cellular concrete representatives
Property | Foam block | Foam gas block | Gas block | Fiber foam concrete |
Thermal conductivity, W*-ms | 0.07-0.36 | 0.05-0.25 | 0.08-0.41 | 0.13-0.4 |
Density, D | 300-1200 | 150-650 | 300-1200 | 300-1200 |
Strength, V | 0.5-12.5 | 0.5-3.5 | 1.0-15 | 1.5-15 |
Frost resistance, cycles | 25-100 | 25-75 | 25-150 | 25-150 |
Water absorption, mm/m2 | 10-15% | 15-17% | 25% | 10-15% |
Because of their exceptional thermal insulation and lightweight nature, cellular concrete blocks are a highly adaptable and effective building material. They are produced by adding gas or air to the concrete mixture, which results in a porous structure. Because of this, the blocks have distinctive qualities that make them perfect for a range of construction uses.
Cellular concrete blocks are made by combining cement, sand, water, and an aerating agent. After that, the aerating agent causes bubbles to form in the concrete, giving the mixture a cellular structure, and it is poured into molds to cure. The blocks are cut to the appropriate size and shape after curing, making them suitable for use in building projects.
The environmental friendliness of cellular concrete blocks is one of its main advantages. Compared to traditional concrete, the production process uses less energy and raw materials, which lowers the overall carbon footprint. Their lightweight design also makes them easier to handle and transport, which lowers labor costs and construction costs even more.
Cellular concrete blocks are a popular option for contemporary construction because they provide a great balance of strength, durability, and thermal insulation. They are an extremely versatile building material due to their ease of production and capacity to modify their properties to suit particular requirements. Cellular concrete blocks are expected to become more crucial to efficient and sustainable building techniques as the construction sector develops.