Foam blocks are quite simple to manufacture, so setting them up home production not difficult. To do this, you just need to purchase 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 concrete that has a cellular structure. These properties are achieved by the presence of closed air bubbles in the thickness of the material. That's why foam concrete blocks have low density and thermal conductivity.

They are very often used as thermal insulation materials(brands D200-D500), and structural and thermal insulation (brand D600-D800) or structural (D900-D1600).

Foam concrete is especially often used in low-rise construction or during construction interior partitions. It is very well processed and can be trimmed to suit the required building parameters. Foam concrete blocks are manufactured in accordance with standard sizes– usually 200x300x600 mm or 100x300x600 mm.

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

• low cost of material;
• 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, ability to absorb moisture from environment, significant shrinkage.

Features of foam block production

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 of manufacturing the material - classic or autoclave. In the first case, it is necessary to make a regular 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 significant pressure. The finished solution is fed into the molds through a nozzle.

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

Required equipment

Required equipment for the production of foam blocks at home:

• concrete mixer. You can also use a special installation for the production of cellular concrete. She implies complex unit, which includes a pressure mixer, an adapter for a sleeve through which the prepared solution is poured into molds;
• compressor. This installation 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;
• form. This equipment for the production of foam concrete can be made independently from plywood, chipboard or regular edged boards.

Foam generator for foam concrete

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

If you plan to start producing foam concrete blocks only for your own needs, you can get by with less powerful equipment. In this case, you can buy a regular concrete mixer, the average cost of which is 3,000 rubles. It is also necessary to additionally purchase a foam generator with a compressor for 20 thousand rubles. If you plan to set up a business producing foam blocks, it is more advisable 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-made foam concrete installations are very easy to use. They occupy small area- about 2.5-5 sq. m depending on power and standard equipment. This complex also includes a grid for loading bulk materials, a vacuum gauge, a rotary pump, a water meter, hoses, and a control cabinet. For home business The ideal model would be PBU-300, the average price of which is 130 thousand rubles.

It has 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?

You can make molds for foam blocks yourself, 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 molds. Their cost will depend on the container and the material from which they are made. On the building materials and equipment market 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 mold measuring 390x190x288 mm - 250 rubles.

Cost of manufactured foam concrete blocks

For example, to build a house you need 20 cubic meters. m of foam concrete blocks. To produce them, you need to buy a concrete mixer, a foam generator and plywood molds. In general, you need to spend about 29 thousand rubles on the purchase of all equipment.

Cost of 1 cubic meter m of blocks is determined by all the necessary costs for their production:

• materials – cement, sand, foaming agent. To get 1 cu. m finished products you need to spend 720 rubles;
• electricity – 11.25 rubles;
• equipment costs - 29,000/20 = 1,450 rubles.

It turns out that the cost of production is 1 cubic meter. 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 the equipment after construction is completed.

Professional equipment

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

The first type of device includes a concrete mixer with an adapter, a compressor, a steam generator, a working platform and a dispenser. When using such a mini-plant ready solution manually distributed into molds, and after setting, removed from them and sent to the autoclave. After final drying, the blocks are completely ready for use. This equipment is delivered to the site as an integral complex. It is easy to install 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 the significant consumption of foaming agents. To obtain a product with optimal characteristics, you need to carefully approach the formulation of the blocks. If you select the necessary components incorrectly, the material will turn out to be of poor quality.

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

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

• a mixing complex, which is additionally equipped with a pneumatic seal and a pump;
• foam generator with compressor;
• water dispenser, which is equipped automatic system management;
• dispenser for binding materials;
• conveyors for sand and cement;
• control panel;
• vibrating sieve

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

To build a warm and eco-friendly house from self-made material, it makes sense to master the production of foam blocks at home. This will save money on purchasing blocks, avoid damage during transportation, and make “bricks” the right size.

Equipment for the production of foam blocks at home

To make blocks from foam concrete, you cannot do without a minimum set of equipment and accessories:

• foam generator - its productivity must be at least 200 l/min;
• compressor;
• concrete mixer – volume from 250 l;
• molds for foam blocks or split formwork.

To regulate and control pressure, it is advisable to connect auxiliary devices and equipment - pressure gauges, pumps.
The forms are made detachable or one-piece. In the first case, they are 2 L-shaped halves of wooden board 20 mm thick, covered with tin, or 4 flat walls made of steel sheet connected by bolts or latches. One-piece equipment is made by welding from a sheet 4–5 mm thick: the walls should be trapezoidal to simplify the removal of products.
It is more convenient to use multi-place forms from moisture resistant plywood, metal or plastic, representing a frame with cells.

To obtain 1 m3 of material with average parameters, 320 kg of cement, 210 kg of sand, 110 liters of water, 1.5 kg of foam concentrate, and a hardener (according to the instructions) are required.

Production of foam blocks, price and types of equipment

If you plan to make cellular blocks just for yourself, you can buy a small concrete mixer for 3,000 rubles, a foam generator with a compressor for 20,000 rubles. For small businesses, it is economically feasible to purchase a ready-made complex for the production of foam concrete and molds for blocks (you can even use it second-hand).
Foam concrete installations are equipped with everything necessary and occupy an area of ​​2.5 - 5 m2. The equipment set, in addition to the required minimum, includes: a grate for loading sand and cement, a rotary pump, a vacuum gauge, a control cabinet, a water meter, and hoses.
The PBU-300 foam concrete installation is very popular (average price 130,000 rubles) with the following technical data:

• volume – 300 l:
• weight – 380 kg
• dimensions – 1.5 x 1.7 x 0.85 m
• productivity – 0.9 m3/hour;
• power – 2.2 kW.

You can make molds for pouring foam blocks yourself. But do it in a makeshift way quite difficult: you need to strictly maintain their dimensions so that the manufactured blocks have the correct geometric parameters. An acceptable option is to buy used equipment. Its cost depends on the material and total capacity. Approximate prices The forms for foam blocks are given in Table 2.

Price of received foam blocks

Initial data. It is planned to build a house 8 x 10 x 2.5 m, for this you need (8 + 8 +10 + 10) x 2.5 x 0.2 = 18 m3 + reserve 2 m3 = 20 m3 of foam block. It is planned to purchase a concrete mixer - 3,000 rubles, a foam generator with a compressor - 20,000 rubles, plywood molds - 6,000 rubles.
To determine the cost of a cellular block, add up the material costs for producing 1 m3 of the product and the costs of equipment, divided by the volume of cast blocks.

1. Materials per 1 m3 (cement, sand, water, foaming agent SDO-M) – 720 rubles.
2. Electricity (2.5 kW) – 11.25 rubles.
3. Unit costs for equipment: (3000 + 20000 + 6000): 20 =1450 rub.

Cost per cubic meter = 720 + 11.25 + 1450 = 2181 rub.
The price can be reduced by purchasing cement at a wholesale price and loading equipment at the end of construction (for example, renting out).

Production technology

The technological process consists of several stages.

The technology of cutting foam concrete is less popular. Using this method, the mixture is poured into a large mold, and after drying, it is cut into blocks of the desired size. At the same time, it is easier to achieve the correct geometry of products, smooth edges and corners - this reduces the cost of correcting defects. However, the block cutting machine abrasive wheels It is not cheap, and, in addition, it is difficult to determine the moment of cutting.
To make the production of foam blocks more profitable at home, it is recommended that after mastering the technology, open a small business and produce foam concrete blocks for sale.

• • Barotechnology
• • Molding technology
  • Cutting technology
• Drying blocks
• Paperwork
• Tax regime
  • • • Similar business ideas:

Foam blocks are a lightweight building material obtained by hardening a solution consisting of sand, cement, water, foam and chemical additives. The popularity of foam blocks is due to a number of advantages of this building material:

• Reliability. It is almost eternal, resistant to negative environmental influences building material;
• Heat. Foam blocks have high thermal resistance;
• Ease. Foam blocks are 2.5 times lighter than bricks and their consumption when laying walls is several times less than the consumption of bricks due to the reduction in wall thickness;
• Soundproofing. A building built on foam blocks has a high ability to absorb sound;
• Quick installation. Due to their large size and precise geometry, laying foam blocks is quite easy and quick.
• and many other benefits.

In this regard, the demand for foam blocks from construction organizations and individuals there is always.

The advantages of producing foam blocks are as follows:

1. Low costs to start a business. To organize a mini-production of foam blocks, about 300 thousand rubles are enough;
2. Simple technology for the production of foam blocks;
3. Stable demand for this building material;
4. To organize production, large areas and a large staff of workers are not required;
5. High indicators of economic efficiency of production. The profitability of foam block production is about 50%.

The production stages of foam blocks are as follows:

At the same time, depending on the type of equipment used and production technology, the quality, cost, speed of production of foam blocks, etc. change. First things first.

Preparation of foam concrete mixture

Today for making foam concrete mixture use two technologies: barotechnology and the use of a steam generator.

Barotechnology

Pressure technology is a cheaper way to produce foam concrete. This method production does not require the purchase of expensive equipment and therefore it is very common in many small industries. The essence of barotechnology is that the main components of foam concrete are fed into the mixer: cement, water, sand, foaming agent, hardening accelerators, air-entraining additives (sometimes). Next, air is supplied to the mixer and all components are actively mixed. Then the resulting solution is fed under pressure into injection molds, where the foam concrete mixture increases in volume and takes on its final shape.

Advantages of this technology:

• Low production cost per unit of production and, as a consequence, low (competitive) unit selling price. The production process using barotechnology is simple and does not require large capital investments. Small production can be opened almost at home.

Disadvantages of this technology:

• Low strength of foam blocks due to the large amount of water used when stirring the foam concrete mixture;
• The pores of foam blocks are large, which also reduces their strength and ultimately affects the load-bearing capacity of building walls;
• Synthetic foaming agents and plasticizing additives used in the process of mixing the foam concrete mixture (to create the mobility of the mixture) negatively affect the environmental friendliness of the finished foam concrete blocks.

Production of foam concrete using a foam generator

The production of foam concrete using a foam generator allows you to mix the components of the foam concrete mixture in the correct dosage, which has a positive effect on the strength and quality of the finished products.

The essence of this technology is as follows: using dispensers, first dry components in the form of cement and sand are fed into the mixer, and then liquid components in the form of water with chemical additives. Then the mixture begins to stir. Next, the finished product is fed into the mixer technical foam and mixed with cement-sand mortar. To create the required density of foam blocks by adjusting the operating time of the foam generator, required quantity foam. Then the foam concrete mixture is supplied under compressor pressure to the installation site or into molds.

Thanks to the precise regulation of the dosing and saturation process, the production of foam blocks reaches a completely different quality level.

Advantages of this technology:

• More high quality ready-made foam blocks. Thanks to the use of pre-prepared foam, the output is more durable foam blocks, without large air pores and with the correct structure;
• The foam blocks are environmentally friendly, since environmentally friendly protein foaming agents are used in the production process.

Disadvantages of this technology:

• High cost of equipment for organizing production;
• More high cost units of production and, accordingly, the high selling price of foam blocks.

Today, the molding of foam blocks is carried out using two technologies: casting and cutting technology.

Molding technology

Casting technology involves pouring concrete mixture into special metal cassette molds. The most common cassette forms have a height of 600mm.

Advantages of this technology:

• Low cost of equipment (cassette molds);
• Simplicity of the molding process.

Disadvantages of this technology:

• Discrepancies in the geometry of finished blocks in height, length and width. This happens because when molding foam blocks, no quality forms, often made in garage conditions. High-quality forms are quite expensive;
• To produce blocks of different sizes, different shapes are required, which increases the cost of purchasing or manufacturing different shapes;
• When stripping, partial damage to the corners and surface of the foam block occurs. This happens due to the block sticking to the walls of the cassette, and when it is removed, it has not yet gained the required strength. Foam blocks in molds need to be allowed to stand for some time (about 10 hours), and due to the rush in production, this rule is often violated.

Cutting technology

Cutting technology consists of two stages of block forming:

A. Casting the foam concrete mixture into a large mold and stripping;

B. Cutting a large block into foam blocks of a given size.

This technology uses special cutting installations with different cutting elements (strings, band saws and chain saws).

The advantages of this technology are obvious:

• Excellent geometry of finished blocks, in accordance with GOST;
• There are no chips or damage to the surface of the foam blocks;
• Possibility of producing blocks different sizes. This is achieved by reconfiguring the pitch of the saw strings.

Disadvantages of this technology:

• When using different cutting elements, the requirements for timely cutting must be met. It is important to cut when the block has already hardened, but has not gained excess strength, otherwise the string will move, which will negatively affect the evenness of the block.

Drying blocks

Depending on the technology for forming foam blocks, the technology for drying products also differs.

With the injection molding production method, drying of blocks can be carried out in two ways:

1. Keeping the products in molds for 10 hours to gain strength and further demoulding the foam blocks;
2. Heat treatment of products in a steaming chamber, which allows the blocks to gain the necessary strength in just a few hours.

With cutting technology, a large block of block is naturally held for 4 - 12 hours and then cut. The time for cutting into blocks of the required size depends on the type of cutting elements and hardening accelerators added to the foam concrete mixture.

What equipment to choose for the production of foam blocks

We list the main equipment used in the production of foam blocks:

1. Pressure installation for preparing foam concrete mixture:

The cost of such an installation is about 100 thousand rubles.

2. Forms used for injection molding technology foam block production:

A collapsible cassette mold for the production of blocks measuring 600×300×200 mm will cost about 30 thousand rubles. Up to 30 blocks are poured into this form at the same time.

3. Foam generator for preparing technical foam:

The cost of a new foam generator is about 90 thousand rubles.

4. Foam block cutting complex:

The cutting complex is the most expensive equipment in the foam block production system using cutting technology. On average, the price of one set is about 500 thousand rubles.

Other equipment used in the production of foam blocks includes: mixing stations, compressors, vibrating screens, etc.

How much money do you need to start a business producing foam blocks:

1. Creation of a mini-production of foam blocks using injection molding technology using a pressure unit to create a foam concrete mixture. To start such a business, about 300 thousand rubles are enough (if premises are found);
2. Mini-production of foam blocks using cutting technology using a foam generator to create a foam concrete mixture. Start-up costs are about 700 thousand rubles;
3. Purchase of a line for the production of foam blocks, including a full range of expensive equipment: mixing stations, foam generators, cutting complexes, etc. The purpose of purchasing such a line is to create an enterprise for the production of large volumes of foam blocks. Start-up costs in this case will amount to several million rubles.

Brief business plan for the production of foam blocks

Let's calculate the economic efficiency of organizing a mini-production of foam blocks, with a production volume of 330 m3 of foam blocks per month (22 working days) or 15 m3 per shift.

Initial data:

1. Productivity per shift - 15 m3;
2. Number of working days (shifts) per month - 22;
3. Production area - 500 m2, rental cost - 50 thousand rubles per month.

How much money do you need to open a mini-production of foam blocks?

The total starting investment for opening a mini production of foam blocks will be 421 thousand rubles.

Material costs for the production of 1m3 of foam concrete

The total cost of materials for the production of 1 m3 of foam block is 1590.13 rubles.

Conclusion: Net profit based on the results of the monthly work of the enterprise for the production of foam blocks will amount to 406.4 thousand rubles. The profitability of production at such indicators is 60%, and the payback period for the equipment is only 1 month. Such indicators are possible subject to 100% sales of all manufactured products, which is 330 m3 of foam blocks per month.

Organization of a business for the production of foam blocks

The procedure for preparing documents for opening and developing your own company for the production of foam blocks includes the following steps:

• Collection of information and analysis of the situation on the building materials market.
• Creating a business plan.
• Analysis of the financial situation (if your own savings are not enough, you need to look for alternative sources of financing).
• Business registration.
• Search for premises for workshop and administration.
• Conclusion labor contracts with company personnel.
• Product certification.
• Purchase of equipment and tools.
• Signing contracts with suppliers, buyers, etc.

Solution to the above
questions is quite a labor-intensive task, so

Many aspiring entrepreneurs turn to law firms in order to receive a ready-made package of documents for a certain fee (the cost of services depends on the region of residence and other factors).

Paperwork

Preparing papers for the legal production of foam blocks begins with choosing a legal form for your business. LLC registration is carried out if the owner of the company plans to work with government agencies And large companies. Entrepreneurs who focus on working with individuals can register as individual entrepreneurs. In addition, you will need the following documents:

• permits from the fire inspection and Rospotrebnadzor;
• certificates;
• invoices for raw materials;
• agreements with counterparties;
• certificate of opening a bank account.

Preparation of documents for the operation of an enterprise that specializes in the production of foam blocks is almost completely limited to the listed issues. For this direction commercial activities no need to obtain permits or licenses. To register a business and subsequent preparation of reporting, banking and other documents, you need to indicate the activity code (according to the all-Russian classifier). In this case, it is OKVED 26.61.

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• for men

Professional modern equipment for the production of foam blocks and high-quality components allow us to produce lightweight and reliable modern building material. The manufacturing process of any lightweight cellular concrete has its own characteristics and nuances, and foam concrete is no exception. Before we begin the review modern equipment for production, we will consider the main features of manufacturing foam blocks.

The process of manufacturing foam concrete blocks can be carried out in two ways: in various ways, each of which has both disadvantages and advantages.

1. Molding method.

During the production process, the concrete solution is poured into an iron cassette mold with removable sides and bulkheads dividing it into several sections. Directly in the mold, the block is dried, and then the completely finished product is removed from it.

The advantage of this method is the absence of a sawing machine in the production chain, which significantly reduces the cost and production time.

Flaws:

• poor block geometry;
• low dimensional accuracy of produced blocks even when using expensive molds;
• a deliberately high percentage of defects, since every block adhering to the surface of the mold is destroyed.

To prevent the destruction of blocks, special lubricating compounds for molds have been created that decompose into outdoors in a few days. The cost of such lubricants is high, but they do not insure against chipping and destruction of blocks.

2. Sawing (cutting).

It is this technology that is most common among manufacturers of foam concrete materials. When using this method, first a foam concrete solution is used to make big block, which, after drying, is sawn (cut) into blocks of the required size.

To cut blocks, a sawing machine for foam blocks is used, which not only saws the resulting mass, but also removes damaged edges.

The advantages of this technology are minimal errors and high precision sizes, as well as the correct geometry of each product.

The disadvantage will be the need to cut the foam concrete mass into small pieces, and this requires special, rather expensive equipment. This increases production costs and production time.

Stages of block production

The main stages of manufacturing foam concrete blocks using both sawing and casting methods, with the exception of certain points, are almost the same. Let's consider, in general outline, the main stages of foam concrete production using injection molding technology:

1. Preparation of foam concentrate, diluted in a separate container with water, and then fed into the foam generator. If there is a cavitation installation, this step is skipped.

2. Mixing and producing foam concrete mixture. All dry ingredients and additives are placed in the mixer, after which foam is fed into it. All components are mixed for several minutes with the mixer hatch hermetically closed.

If a cavitation installation is used, then the foaming agent is put into the mixer first, before all the other ingredients are added there, after which the mixture is kneaded for about half a minute.

3. Filling out forms. Before you start filling the molds, they must be cleaned and lubricated with machine oil or special lubricating fluids. After this, the resulting foam concrete solution is poured into molds and the top side is leveled.

4. Hardening of foam concrete. Filled molds should be stored at an ambient temperature of approximately +20 °C. If this condition is met, the foam blocks will reach 25% of the designed strength in 8-10 hours, which will allow them to be packaged.

Methods for making foam concrete blocks

We have already discussed one of the methods for making blocks, namely the method of pouring foam concrete into special cassette molds. There are two more:

• Sawing or cutting solid foam concrete using special equipment.
• Pouring foam concrete composition according to special forms, followed by automatic formwork removal.

Types of equipment for the production of foam blocks

Today it is not difficult to buy equipment for the production of foam concrete blocks, either individually or as a set. It is quite easy to get confused by the number of units offered by manufacturers and sellers, which differ in performance, size and configuration of units. It is important to clearly establish how many blocks you need and whether your finances are enough to organize production.

The production of cellular foam concrete and blocks from it is impossible without the following equipment:

• vibrating screen (for sifting materials);
• raw material supply device (sand, cement);
• water dispenser;
• mixer;
• foam generator (except for installations using pressure technology);
• compressor;
• hose for supplying the finished solution;
• forms various types either sawing machine or band saws.

To understand all this variety of equipment, let's look at what it is like.

All settings can be:

• stationary;
• mobile.

A special subtype of stationary installations for foam concrete are conveyor and automatic lines.

Fixed lines

Stationary complexes for the production of foam concrete blocks are produced on the basis of various foam generators. Capable of producing up to 110 m3 per day.

Advantages:

• High performance.
• Low consumption of foaming agent for each m 3 of the resulting material.
• Production of high-strength foam concrete.
• Reducing production costs.

The price of stationary lines for the production of foam blocks is quite high, as can be seen from the table below:

Mobile equipment

A mobile installation for the production of foam concrete does not involve the use of a foam generator during the production process. As a rule, equipment of this type operates on the principle of pressure technology, and is characterized by low productivity, up to 45 m3.

• The easiest way to produce foam concrete and blocks from it.
• The absence of a steam generator leads to a reduction in the price of such installations.

• Low productivity.
• High foam concentrate consumption.
• Not very high strength of the resulting material.

In the table below, you can see prices for equipment for foam concrete in the category of mobile machines.

A special feature of the Fomm-Prof500 is the presence of a Fomm-PGM foam generator that works using the GreenFroth protein foaming agent, which makes it possible to obtain foam concrete of higher strength than, for example, on a Sunny pressure unit.

In addition to BAS-130, Sunny-014 and Fomm-Prof500, there are many other mobile installations and complexes on the market, including foreign ones, such as RSG-500, DSL-150. All of them have good performance and are quite affordable prices in the range from 50 to 100 thousand rubles. However, all these installations have a serious drawback - underdeveloped customer service and possible delays in the supply of spare parts.

Automatic and conveyor lines

To organize automatic or conveyor line For the production of foam concrete blocks, a fairly large room is needed, since it is necessary to organize five main production areas in it:

• Cement warehouse with automatic dosing.
• Sand warehouse automated by dispenser.
• Automated line for dosing and supplying cement, water and sand.
• Foam concrete production line.
• Place for cutting foam blocks or automatic stripping of forms.

Productivity ranges from 80 to 100 m 3 blocks per shift.

Below is a table in which you can see both the performance and prices of this equipment:

Today it is in high demand automatic line"Fomm-Pusk" produced by the St. Petersburg company "Stroy-Beton". Contains:

• automatic dosing complex;
• automatic control system;
• automatic water supply system;
• storage and supply systems for sand and cement;
• production plant "Fomm-Prof".

Thus, if equipment is needed for individual construction, a used machine for producing foam blocks at home is quite suitable. If you need to get more blocks, such as a small construction crews, then mobile installations are suitable. Small commercial organizations, depending on the expected production volumes, both mobile and stationary lines are suitable.

Foam concrete is in demand in construction as it is inexpensive, but quality material. It is lightweight, retains heat well, and has good soundproofing qualities. Foam blocks are fireproof, have very low coefficients of water absorption and shrinkage, and tolerate any atmospheric changes well. The production technology is quite simple and environmentally friendly, so making and selling blocks can become a profitable home business.

Materials for foam concrete

Producing foam blocks at home requires certain costs. For production 1 cubic meter(or 720 liters of foam) required:

• Cement. On average, about three hundred kg are required. Cellular concrete (this is another name for blocks) can have different densities, so for the manufacture of foam concrete for various purposes and density requires cement various brands. Which ones are determined by State Standards and Technical Conditions. Below you will see a table indicating the required cement parameters.
• Purified sand, river: about 200 kg.
• Water: 100 liters + 50 liters for foam.
• Foaming agent (synthetic or from natural ingredients): - about two liters, depending on the density of the blocks. The most popular and affordable foam concentrates are PB 2000 or “Lux” (USHK), SDO-M (Technology LLC), FOAMIN C (Italy), “Forward” (Roskosmetika LLC).
• Hardener.
• Mold lubricant.

Equipment for the production of foam blocks

In order to make blocks with your own hands, you will have to purchase equipment. You will need:

• A steam generator capable of producing at least 200 liters per minute.
• Compressor installation.
• Mixer hopper. For beginning entrepreneurs, a unit with a power of 2.2 kW and a working volume of about 280 liters is sufficient.
• Mold for standard blocks 200x300x600mm.
• Auxiliary instruments: pressure gauges, pumps.

Equipment in the form of a ready-made kit can be purchased in special stores. You can also make equipment to order. The second method is much more expensive and is financially justified only when home production has reached full capacity.

When organizing production, a room should be equipped for drying finished blocks. It is also important to take into account the total power consumption to ensure uninterrupted operation of the equipment.

Do-it-yourself foam concrete block manufacturing technology

One installation can produce blocks different densities. Depending on the proportions in which the components are taken, you can get cellular concrete density from 200 to 1500 kilograms per square meter.

The production process is very simple. Three independent processes can be distinguished in it:

1. Preparation of sand-cement mixture. The proportions depend on the expected density of the finished material, which is determined by GOSTs and technical specifications. To receive medium density Usually equal amounts of cement and sand are taken.
2. Preparation of foam solution. For medium-density blocks, 4-5 grams of concentrated foaming agent is sufficient.
3. Pouring the resulting mixture into standard molds.

Preparing a mixture of sand and cement

To prepare the mixture, use Portland cement M-400, 500 and fine, without clay impurities quartz sand. You can take tap water: it is most often free of acidic or alkaline impurities. Approximate proportions for producing foam concrete that meets GOST 21520-89 and 25485-89 are shown in the table:

Preparing the foam concentrate

If a ready-made foaming agent is used in production, then it is enough to mix it with water to obtain a ready-made working composition. Some people make their own foaming agent. Its price is lower, but labor costs are higher.

How to make a foam concentrate yourself? Grind and mix 150 g of caustic soda, a kilogram of rosin and 60 grams of wood glue. The composition is heated and mixed until a homogeneous consistency. Considering that the production of such a foaming agent takes quite a lot of time and effort, it is economically feasible, many entrepreneurs believe, to buy a ready-made foaming agent.

Preparing forms

Typically, forms are included in a ready-made set of equipment designed for creating foam blocks. However, you can make them yourself from plywood or sheet iron. In this case, it is important to accurately observe the geometric shape of the forms: otherwise the finished blocks will not meet the requirements. For lubrication, emulsions, solutions or suspensions can be used.

Solutions can be prepared from spindle oil or grease, autol or petrolatum, diluted in kerosene or oil (solar).

Suspensions include ready-made cement-oil, lime, chalk, graphite, etc. lubricants

Emulsions can be of two types

The first ones can be made:

• From 10-15% hygrol 3 brands, 1% laundry soap and 85-89% water.
• 10% acidic synthetic emulsol, 0.6% soda and 89% water.

The second ones make:

• From emulsol (20%).
• Diesel fuel (5%-10%).
• Saturated lime solution (70%-75%).

Block production

A mixture of sand and concrete is placed in the mixing hopper, mixed well, water and the prepared foaming agent are slowly added, and after the formation of a stable foam, a hardener is added. The most accessible hardener is calcium chloride. Typically its amount is 1% -2% of the amount of cement. After 2-3 minutes of mixing, the composition is ready. It is poured (transported) into pre-treated lubricants and dried for 48-60 hours at a temperature of 50°-60°.

Training video on the production of foam blocks

In this video you can watch the process of producing foam blocks using a ready-made set of equipment:

To prevent surface cracking, cover the molds with the mixture. plastic film. The mixture can be poured into large containers, and then the semi-dried composition can be cut. The finished blocks are placed in pallets and sent to the construction site.