Production of aerated concrete blocks. preparation of the

The line for the production of aerated concrete blocks can be the main reasonably profitable private business. This is due to the fact that the technological process of manufacturing this material is not complex, and with fundamental theoretical training you can get a large amount of quality products with relatively small investments.

Below we describe how the building gas-block is made, and what nuances of technology you should pay attention to.

General scheme of work

Газобетон представляет собой ячеистый материал, который используется как для возведения несущих конструкций, так и для утепления уже существующих стен (см.также статью «Срок службы бетона: продляем время эксплуатации бетонной конструкции»).

Note! The purpose of the blocks depends on their density. The group of structural materials includes products of class D1000 - D700, and for thermal insulation the modules D400 are most often used.

The production technology of aerated concrete blocks includes several stages:

• First, we prepare a mixture of components, the most important of which is a gas-forming material.
• The mixture is then poured into forms in which the reaction takes place. At this time, pores are formed in the thickness of the solution, and the cement granules begin to gain hardness.
• After preliminary curing, the hardened monolith is sent for cutting, where it is sawn with thin steel strings in accordance with the configuration of the modules.

• It is also possible to cast in cassette molds, in which cutting is not required: the equipment for the production of aerated concrete blocks is adjusted so that the products from the mold go out in the right size.

Then comes the turn of drying. The quality of this operation determines how strong the building material will be.

Depending on the processing conditions, aerated concrete is divided into two types:

• Autoclave - removal of fluid and the final curing is carried out in special devices under pressure and when exposed to high temperature.
• Non-autoclaved - hardening occurs in natural conditions. This type is much easier to do with your own hands, and its price is lower, but autoclave blocks are many times superior in strength.

Description of the stages

Preparation of the mixture

If the information outlined above inspired you and you are ready to buy used equipment for the production of aerated concrete blocks, then you should either hire a competent technologist or learn the basics of production yourself. First of all, we recommend reading all the tips in this section.

As we noted earlier, the technological cycle begins with the preparation of the composition.

The most commonly used proportions are given in the table:

Note! To improve the quality of the material, the instruction recommends taking sand with a mass fraction of clay not more than 7%.

• First, we prepare a suspension from water and aluminum powder. The resulting composition is constantly mixed in order to avoid delamination.
• After that we introduce the suspension into a mixture of cement, sand and lime, add water and mix the material until smooth.

Filling and drying forms

In parallel with the preparation of the composition, the following operations are performed:

• Forms (cassette or for the manufacture of monolith for cutting) assembled from individual parts.
• For connection use bolts or special detachable fasteners.
• Inside, we lubricate the molds with machine oil, which will make it easier for us to remove the building blocks after drying.
• We fill the tanks with a solution, compacting it to remove large air bubbles.

After this, the primary set of strength occurs. This process usually takes from three to six hours depending on the composition of the solution. During curing, it is desirable to protect the form from sudden changes in temperature, as this may lead to cracking of the blanks.

After the primary drying is completed, the parts are removed from the containers and subjected to further processing.

Sawing and final curing

In the industrial manufacture of aerated concrete modules, monolith sawing technology is commonly used.

It is carried out according to the following scheme:

• Hardened billet of a large size is removed from the mold and fed to the sawing machine.
• With the help of wire or band saws of small thickness, the monolith is cut into fragments of the desired size.
• In some cases, mounting slots are cut out on the blocks. In this case, the saws are controlled using a special computer program.

Note! Cutting technology allows you to make modules with a deviation in size of no more than 1 mm upwards or downwards. This greatly facilitates the work on the construction of a masonry of aerated concrete.

But the mini plant for the production of aerated concrete blocks, which is used in private production, is rarely completed with saws.

Here another method is usually applied:

• Instead of a form for pouring monolith, constructions with internal jumpers are used.
• In the process of pouring, the solution is distributed into the cells of such a cassette, and curing is carried out in the desired form.
• After curing, the blanks are removed from the cassette and, bypassing the cut, immediately go to the drying area.

The disadvantage of this method is the risk of violation of the geometric shape of the blocks. However, with due care in assembling and casting this can be avoided.

At the final stage, autoclaving is carried out: the blanks are placed in a special chamber, which is hermetically closed. Further, air is injected into the working area to create a pressure of about 12 atmospheres, and at elevated temperature the final “maturation” of the material occurs.

Conclusion

Линия по производству газобетонных блоков может работать достаточно эффективно только в том случае, если все технологические процессы будут правильно спланированы. Вот почему для получения качественного строительного материал, который будет отличаться хорошими эксплуатационными характеристиками и пользоваться спросом, нужно внимательно изучить нюансы всех методик (см.также статью «Строим дом из газобетона экономно»).

To get started is to watch the video in this article, and then - begin to master the technology in practice.