As you know, in our time, "simple" concrete, i.e. without various additives and additives that improve its properties, it is practically not used. Various additions change and improve the structural performance of concrete blocks and make them suitable for use in a wide variety of structures. Therefore, the topic of production of foam and aerated concrete is relevant.

First of all, high rates of thermal insulation and soundproofing are required from concrete blocks. Sometimes the production of such concrete blocks is successfully combined with other industries and waste from them is used - for example, expanded clay, foam plastics are added to concrete before pouring into block forms, mineral wool, wood and even various slags. This leads to the formation of concrete blocks with new properties - for example, buildings built from them lose less heat in winter and do not overheat in summer; in addition, by reducing the specific gravity, the load on the foundation is significantly reduced, etc.

But to combine two industries at the same time - for example, a sawmill and a cement plant, in fact, turns out to be quite difficult. Therefore, in the construction industry, special foam or gas is used to produce cellular concrete.

Hence the name of two materials that are currently in great demand: aerated concrete and foam concrete.

How are aerated concrete and foam concrete produced?

Aerated concrete is produced by introducing into the cement mortar special substances that cause the process of gas formation, or simply releasing gas at a certain chemical reaction. The main component in this case is aluminum powder, which reacts with products released during cement hydration. From the point of view of chemistry, hydrogen is released, causing the process of pore formation in the cement slurry. Visually, it looks like dough after yeast has been added to it. The cement mass begins to increase in volume and after it hardens, porous concrete is obtained.

Foam concrete is produced by mixing cement mortar with a special foam prepared in advance. In this case, the foam bubbles, which contain air, are evenly distributed throughout the volume of the mixture. The effect of porosity, like that of the previous material, persists after solidification.

Usually, both types of concrete blocks are used for construction: load-bearing walls are made of more durable aerated concrete blocks. They bear the main structural load. Foam concrete blocks, which are 20-25% cheaper, are used for non-load-bearing partitions and bulkheads.

As you can see, it is most expedient to produce both types of concrete blocks.

Material costs for the launch of a mini-factory for the production of aerated concrete and foam concrete

Consider the investment required to open joint foam concrete and aerated concrete equipment.

A mini-factory for the production of foam concrete will cost, depending on the capacity, i.e. the volume of concrete produced in 105600-283800 rubles. (capacity 10 cubic meters - 30 cubic meters per shift). For the production of aerated concrete - 29800-85000 rubles. (capacity 12 cubic meters - 50 cubic meters per shift).

In addition, a foam concrete mini-plant will require a foam generator (27,800 rubles) and a compressor (37,800 rubles) and a peristaltic pump (57,700 rubles).

Forms for the production of concrete blocks of various sizes will cost from 28,000 rubles. up to 40,000 rubles (1 cubic meter of mixture is pumped into 1 mold, so, for example, with a plant capacity of 10 cubic meters, 10 molds are required).

Total: the minimum investment is 538,700 rubles, the maximum is 1,332,100 rubles.

• 1 cu. m of foam blocks costs about 3000 rubles.
• 1 cu. m of gas blocks costs about 3600 rubles.

Consumables (per 1 cubic meter):

1. Foam concentrate 75 rub. per 1 kg (for foam concrete)
2. Aluminum powder 500 g, 105 rubles. per 1 kg (for aerated concrete)
3. Sand 300 kg - 350 rubles. per cubic meter (1.3 t)
4. Cement - 100 kg (2 bags of 189 rubles each)

As you can see, the material costs are insignificant: about 540 rubles. for 1 cu. m of foam concrete or 520 - for aerated concrete.

How much can you earn in the production of concrete blocks?

Gross profit from 1 cu. m of foam blocks is equal to 2460 rubles, gas blocks - 3080 rubles. If we take production equal to 10 cubic meters. m per day (5 - foam concrete and 5 aerated concrete), the monthly gross profit is equal to about 665,000 rubles.

Net profit, minus wages for workers, utility bills (the production of concrete blocks is quite water and electricity intensive), will be at least 30-35% (about 200-220 thousand rubles) per month.

It turns out that if you return half of the net profit, for example, for the equipment for the production of concrete blocks purchased in installments, it will pay off in six months, and when you purchase the most powerful equipment, the payback will be even faster - about 3-4 months.

This will come at the cost of more production. In general, it is more expedient to purchase the most powerful equipment: with a price difference of 2.5 times with the smallest, it produces 5 times more products.

In addition, with the proper development of the business, it will also be possible to produce, for example, paving slabs and decorative (multi-colored) blocks, which are much more expensive than normal ones.

Videos about the production of aerated concrete and foam concrete

Attention! The free business plan provided for download below is an example. Business plan, the best way corresponding to the conditions of your business, you need to create with the help of specialists.

The ever-growing demand for Construction Materials, due to the development of the construction of private houses, made such a type of business as the production of foam blocks especially relevant.

The simple plan for the production of foam blocks below provides for certain investments from a novice entrepreneur, since any production activity needs start-up capital.

First, it is necessary to analyze the existing demand in the market in a particular area, as well as assess the competition.

If there are a sufficient number of potential buyers, and competition between manufacturers is weak, then you can proceed further.

Secondly, you will need to rent a room in which production activities will be carried out. The premises are selected taking into account the location of potential buyers of foam blocks.

The area of ​​this room is determined depending on the number of products produced at a time. So, for 30 cubic meters of foam blocks, an area of ​​\u200b\u200babout 300 square meters will be required daily.

Thirdly, you will need to purchase a production line on which the mixture will be prepared, foam blocks molded, and dried.

The cost of this line today is 800-900 thousand rubles, while it should be ensured that the equipment provides the opportunity to produce blocks of various densities.

Fourth, you will need to hire staff. For the production of the above volume of foam blocks on the production line, at least six workers will be required, their total wage for any regions, except for the central ones, will be approximately 100-110 thousand rubles per month.

Fifth, you need to calculate the total costs. In addition to the initial equipment purchase costs and monthly salary costs, you will need:

• 1) rent a room - 40 thousand rubles per month;
• 2) purchase sand, cement, foaming agent - about 60 thousand rubles per shift (in the production of 30 cubic meters per day);
• 3) pay for electricity - about 500 rubles per shift.

Thus, the net profit from each cubic meter will be equal to 817 rubles. Taking into account the indicated production volumes, taxes and contributions to state funds, the payback period for the business will be 4-5 months.

Foam blocks are quite simple to manufacture, so it is not difficult to establish their home production. To do this, you just need to buy everything necessary materials and equipment. At the same time, some units for the production of foam concrete blocks can be made independently.

General description of the material

Foam concrete is called concrete, which has a cellular structure. These properties are achieved by the presence of closed air bubbles in the thickness of the material. Therefore, foam concrete blocks have a low density and thermal conductivity.

They are very often used both as heat-insulating materials (grades D200-D500), and structural and heat-insulating (grades D600-D800) or structural (D900-D1600).

Foam concrete is especially often used in low-rise construction or in the construction of interior partitions. It is very well processed and can be cut according to the desired parameters of the building. Foam concrete blocks are made in accordance with standard dimensions - usually 200x300x600 mm or 100x300x600 mm.

When using foam blocks in private construction, you can get the following:

• low material cost;
• excellent thermophysical characteristics;
• ease of processing and installation;
• light weight of the blocks, which does not create additional load on other structures;
• environmental friendliness of the material.

The disadvantages of foam concrete include its low strength, the ability to absorb moisture from environment, significant shrinkage.

Features of the production of foam blocks

In order for the profit from the production of foam blocks to be high, this issue should be taken seriously. First of all, you need to choose a method for manufacturing the material - classic or autoclave. In the first case, it is necessary to make a conventional cement mortar, into which air is supplied using a foam generator. After thorough mixing, the mixture enters the prepared molds, where it reaches its design strength.

When using the autoclave method, all components of foam concrete are mixed under considerable pressure. The finished solution is fed into the molds through a nozzle.

There is also another manufacturing technology for this material - mixing dry components with subsequent mineralization. It is quite complex, therefore it is mainly used in mass production.

Necessary equipment

Necessary equipment for the production of foam blocks at home:

• concrete mixer. You can also use a special plant for the production of cellular concrete. It implies a complex unit, which includes a pressure mixer, an adapter for a sleeve through which the prepared solution is poured into molds;
• compressor. This installation is necessary for supplying compressed air to other units - a steam generator device, a mixer for supplying the finished solution;
• steam generator. This unit produces a special fine-pored foam, which consists of water, air and a special foaming agent;
• the form. This equipment for the production of foam concrete can be made independently from plywood, chipboard or ordinary edged boards.

Foam generator for foam concrete

How much do you need to invest to start a business?

If you plan to set up the production of foam concrete blocks only for your own needs, you can get by with less powerful equipment. In this case, you can buy a conventional concrete mixer, average cost which is 3000 rubles. It is also necessary to additionally purchase a foam generator with a compressor for 20 thousand rubles. If you plan to establish a business for the production of foam blocks, it is more expedient to buy a ready-made set of equipment and molds. In this case, you can use not only new units, but also used ones (in good condition).

Ready foam concrete installations are very convenient in operation. They occupy a small area - about 2.5-5 square meters. m depending on power and standard equipment. This complex also includes a grate for loading bulk materials, a vacuum gauge, a rotary pump, a water meter, hoses, and a control cabinet. For home business will be perfect model PBU-300, the average price of which is 130 thousand rubles.

It is distinguished by the following characteristics:

• working volume is 300 l;
• productivity - 0.9 cubic meters. m/hour;
• power - 2.2 kW;
• weight - 0.38 t;
• dimensions - 1.7x1.5x0.85 m.

What to do with forms?

Forms for foam blocks can be made independently, but it is very difficult. It is very important to monitor the accuracy of all parameters so that the resulting material has ideal dimensions. Therefore, for a home business, it is best to find used uniforms. Their cost will depend on the capacity and the material from which they are made. In the market of building materials and equipment, you can find approximately the following prices:

• steel molds (36 pieces), where the cell size is 600x300x200 mm - 32 thousand rubles;
• steel molds (22 pieces), where the cell size is 600x300x200 mm - 10 thousand rubles;
• plywood molds (22 pieces), where the cell size is 588x300x188 mm - 6 thousand rubles;
• one plastic form measuring 390x190x288 mm - 250 rubles.

The cost of manufactured foam concrete blocks

For example, to build a house, you need 20 cubic meters. m of concrete blocks. For their production, you need to buy a concrete mixer, a foam generator and plywood molds. In general, about 29 thousand rubles should be spent on the purchase of all equipment.

The cost of 1 cu. m of blocks is determined by all the necessary costs for their manufacture:

• materials - cement, sand, foaming agent. To get 1 cu. m of finished products must be spent 720 rubles;
• electricity - 11.25 rubles;
• equipment costs - 29000/20 = 1450 rubles.

It turns out that the cost of production of 1 cu. m of foam blocks are 2181 rubles. The final cost of the material can be reduced by purchasing all materials in large quantities at a wholesale price and renting out equipment after construction is completed.

professional equipment

When choosing equipment for the production of foam blocks, you should pay attention to mobile mini-factories or stationary conveyor lines.

The first type of devices includes a concrete mixer with an adapter, a compressor, a steam generator, a working platform and a dispenser. When using such a mini-plant, the finished solution is manually distributed into molds, and after setting, it is removed from them and sent to the autoclave. After the final drying, the blocks are completely ready for use. This equipment is delivered to the object in the form of an integral complex. It is easily mounted and does not require commissioning.

As a result of the production of blocks using mobile mini-factories, material of average quality is obtained. Also, the disadvantages of this equipment include a significant consumption of foaming substances. To obtain a product with optimal characteristics, you need to carefully approach the recipe of the blocks. With the wrong selection of the necessary components, the material will turn out to be of poor quality.

Stationary conveyor lines differ from the previous equipment in their high power. It is able to work around the clock, providing a performance of 5-12 cubic meters. m/hour.

Typically, such conveyor lines are equipped with the following units:

• mixing complex, which is additionally equipped with a pneumatic seal and a pump;
• foam generator with compressor;
• water dispenser equipped with automatic system management;
• dispenser for binders;
• conveyors for sand and cement;
• Remote Control;
• vibrating sieve.

Considering all the features production process for the production of foam concrete blocks, both on a small and large scale, it is clear that this is a very profitable business. This material is popular in the market, so it will always be in demand among buyers.

Foam concrete production technology

The popularity of foam concrete has increased significantly in the implementation of construction activities. Buildings built of foamed concrete are characterized by a high degree of thermal insulation and provide a comfortable temperature regime of the room. The production of foam concrete is carried out at a growing pace, which allows us to meet the requirements of developers as much as possible.

Currently, the products are in demand in the market of building materials and are used in the construction of cottages, country houses, redevelopment, and insulation of premises. Briefly describe foam concrete, it is a hardened array, including foam concentrate, Portland cement and water.

Foam concrete is a type of concrete that has a cellular structure.

The technological process of manufacturing a composite is quite simple, but it requires certain knowledge. For beginners who have not encountered the production of this material, the manufacturing process presents some difficulties. The development of production requires significant financial resources to create a high-quality composite.

The foam concrete production technology is based on the use of high-quality raw materials, the performance of work using special equipment. This contributes to cost-effective, high-quality products that meet customer requirements.

Components for the preparation of the foam mixture

The production of foam concrete blocks is carried out according to recipes that regulate the percentage of ingredients depending on the required density of the composite. All types of recipes include the following components:

• Portland cement, marking M400 and above. An increase in the brand of cement improves the quality characteristics of the foamed composition.
• Aggregates, which can be used large fractions of expanded clay, doubling the strength of the porous composition. The use of fine sand provides a density of 0.6 t/m³. More preferred river sand, having a size of up to 0.2 mm, which does not contain foreign inclusions. It is not allowed to exceed the clay concentration by more than 3%.
• Water, the percentage concentration of which is determined by calculation. Prior to the introduction of foam, the ratio of water and cement should be at least 0.38. A decrease in the water-cement ratio causes an increase in the volumetric weight of the product. This is because the concrete absorbs water, partially disrupting the foam, causing it to decrease. The optimal proportion of the ratio of water to cement is 2:5. The water temperature should not exceed 25 degrees Celsius.
• Foaming agent, which is used as a foam concentrate based on protein, bone glue or pine rosin. The shelf life of the composition should not exceed two to three weeks from the date of preparation. The temperature regime during storage is in the range from 5 to 30 degrees Celsius.

Foam concrete, the technology of its manufacture is so simple that, if desired, it is easy to reproduce even at home

Manufacturing methods

Methods for the production of foam blocks can be different. When deciding on the development of production, one should decide on a technology called:

• classical, in which foam is introduced into the pre-prepared cement-water composition, coming through the lines from the foam generator;
• barotechnology, which makes it possible to obtain a foam concrete composite without the use of a foam generator. The process includes whipping high frequency the working body of the abundant foam mixer, into which sand and cement are introduced;
• porous, used for pouring a foam mass, filling voids, pouring ceilings directly in the conditions of a construction site. Production is carried out using mobile units that allow you to separately prepare a cement-sand mortar, pump water. The porizer produces high-quality foam supplied along the highway. At the same time, the finished foam concrete is fed into the mold through special hoses, where it solidifies.

Depending on the type of foam concentrate used and the technology adopted, the foam concrete preparation method is selected.

Classic technology

Let us consider in more detail the classical method of production, which is the most common method for the manufacture of foam concrete.

The production of foam concrete in the classical way provides for the following equipment and tools:

• Devices for mixing concrete.
• sifter.
• Connecting highways.
• Steam generator.
• Devices for dosing water.
• compressor.
• A set of precise molds for casting products.
• Loader for automated supply of raw materials or tools (buckets, shovels) for manual work.

Stages of work execution include the following stages:

• preparation of the necessary ingredients (cement M500, fine sand, water);
• preparation of a foamed mass by introducing a pre-diluted foam concentrate into a foaming agent container;

The prepared mixture is transported by means of a pump into a monolithic structure or mold

• production of foam concrete composition, for which sand and cement are loaded into the mixer, they are mixed until a uniform consistency is ensured. Then water is introduced and the prepared foam coming from the foam generator, which is intensively mixed with the cement-sand mortar for 3 minutes;
• molding products into containers previously lubricated with a special molding composition, where the foam concrete composition must settle for 12 hours;
• drying products after dismantling the formwork, extracting finished products on pallets. The final hardening of products is carried out in the room.

The duration of solidification of the array is determined by the temperature regime of the room and is:

• Two days at a temperature of 22 degrees Celsius. During this time, the products acquire up to 70% of the required strength.
• Eight hours if the temperature is maintained at 50 degrees Celsius during this time.