We will learn about equipment for the production of aerated concrete blocks: raw materials, manufacturing process. Equipment required in the production of aerated concrete blocks Equipment for the production of aerated concrete blocks

Private houses are often built from aerated concrete, because this material, at a low cost, has excellent performance. Aerated concrete has been used in construction for a very long time. He has proven himself with positive side if low structures are erected (up to four floors).

The production of this material is a complex and responsible process. Only if all conditions are met, high-quality products will be obtained that can be safely used in.

The main stages of production:

• Preparation of forms. The most commonly used rectangular design, consisting of four sides and two. All parts of the structure are connected by bolts, which are treated with any engine oil.
• Mixture preparation. The initial components of the mixture are cement, lime, sand and warm water. A gas generator is also used. Sand must be screened to a maximum size of 2.1 units. The content of clay in the sand should not be more than seven percent. As for cement, the M-400 or M-500 grades are taken. The ratio of components is approximately the following: 51-71% cement, 0.04-0.09% aluminum paste, 1-5% lime, 20-40% sand and 0.25-0.8% water.
• Form fill. The mixture is poured into prepared forms, which must first be heated to 40 degrees Celsius. After the mixture is poured, its level is leveled with a stretched string. Then it is covered with thermal insulation material. This will reduce heat loss, which is necessary for the stable process of pore formation and hardening of the product.
• Block drying. It is carried out within two hours after pouring. The block is pulled out of the mold and sent to a warm warehouse or special chambers to complete the production process.

Aerated concrete wall blocks are products made of cellular concrete. What are its features and what in general is this construction material.

Aerated concrete was invented a long time ago, but with the development of new modern production technologies, improved aerated concrete blocks began to be produced. various designs and types. When building buildings, several types of different blocks are used. about aerated concrete blocks for external walls.

Equipment for the production of

Depending on the volumes in which aerated concrete blocks are produced, the equipment will be different. Most often it is about fixed lines. They are suitable for the production of non-autoclaved aerated concrete.

Autoclaved aerated concrete gains strength under high pressure and temperature in a special chamber called an autoclave. The non-autoclaved version cures naturally using heat.

The maximum productivity of a stationary line is 60 cubic meters. This is an automated production that requires minimal human presence.

Special equipment helps storage and transportation, and automatic dispensers measure out themselves required amount components. The blocks are of high quality, but this is an expensive equipment, which also requires a large area.

There are also mini lines, which are a reduced copy of stationary equipment. Here the work process is similar to the process described above, and the blocks are obtained good quality. The only difference is the smaller number of finished products.

The video shows the process of industrial production of aerated concrete:

Production molds

The method of stripping affects what forms of production of cellular aerated concrete exist:

• Collapsible. The mass poured into such forms can be combined by simply removing the sides. They are collected on empty pallets. Much of the form work is done by hand, but this increases labor costs.
• Cap. Such forms can only be removed from already frozen blocks. Removal is carried out by mechanical devices. Their frame is cast and cannot be disassembled. Such molds speed up the production process, but also require minimal manual labor.

After removing the finished blocks from any type of container, it must be cleaned and well lubricated before starting a new batch.

How to make aerated concrete blocks with your own hands

You can make aerated concrete at home using special equipment. For example, the mobile installation "Aerated Concrete-500 B Plus" will help. The purchase of such a machine will eventually pay for itself, because it will be possible to produce the required number of blocks for their further construction during the construction of a frequent house without extra financial costs for finding a manufacturer and delivery finished products.

The installation also includes:

• Electrical engine;
• Filling hose;
• Disc with full description all stages of work. Therefore, in order to start manufacturing, it is not necessary to have a special qualification. It is enough to familiarize yourself with the information on the disk.

And this is how they make aerated concrete with their own hands:

Cost of equipment

The final price depends on the capacity of the equipment and its specific configuration. Expensive everything is a mixer, the main part of the price of which consists of dispensers and forms. The mini line will cost around 400,000 rubles. If we talk about the conveyor line, then the total minimum price will be in the region of two million.

Despite the fact that aerated concrete blocks are already a proven building material that has been used for a long time, it does not lose its relevance. The production is characterized by a significant simplicity of the process, and the use of natural materials for the mixture gives the finished blocks many advantages.

The gas block is quite in demand, so the creation of your own mini-factory for its manufacture fully pays off in a short time. The standard equipment includes: mixers, crushers, precise dosers, vibrating sieve. You will also need conveyors, a machine for cutting elements optimal sizes and molds to fill. If autoclaved aerated concrete is produced, then a material heat treatment compartment is additionally needed.

The main factors for choosing lines include area, power consumption, productivity and the need for human resources. All this affects the final value of investments:

• The minimum cost of a standard complex is 400 thousand rubles.
• Opening a mini-line - 250 thousand rubles.
• When buying used equipment, you can save up to 20% of your money.

Raw materials for making blocks

The main component is Portland cement grades M400, M500 and M600. Further, fillers, blowing agents, water and additives that increase the plasticity of the solution are needed. Sand, ground metallurgy waste, ash, lime, dolomite flour should be attributed to inert. The ratio of these additives affects the density and cellularity. For products with high thermal insulation characteristics, they are sufficient in a minimum amount.

To give a porous structure, it is most practical to use aluminum powder PAP-1 and PAP-2. This powder is layered and is available in metal barrels. There are practically no requirements for water. For breeding, you can use plain water from a water supply or reservoir, but without the presence of silt particles or dirt. Before making it is heated to the optimum temperature + 42-43°C.

Consumption per 1 m3 depends on the purpose of aerated concrete blocks, as well as the final marking:

1. Aerated concrete M500: cement M400 - 300 kg, filler (sand) - 200 kg, aluminum powder - 0.7 kg, water - 290-300 l.
2. M600 aerated concrete: M400 cement - 342 kg, filler - 230 kg, PAP-1 powder - 0.6 kg, water - 330 l.

When calculating the volume fraction of the binder, the volume of dry components is 60%, inert additives - 40%. The fillers include 15% lime, 15% dolomite flour and 10% waste removed from products and diluted in water (“pink”). The production of aerated concrete blocks can be considered waste-free. If the cement is not fresh enough, the amount of blowing agent per 1 m3 is increased by 250 g.

Additional fillers are used to obtain specific material ratings required by the manufacturer. To provide increased performance, various plasticizers are added to the composition. Generic marks do not need them.

How is aerated concrete made?

Before autoclaving, the following work steps are carried out:

• Preparation and dosing of the necessary components except for the blowing agent. Their intensive mixing in the mixer until a homogeneous mass is obtained within 5-7 minutes.
• Introduction of aluminum powder and further mixing for 1-2 minutes.
• Pouring the prepared solution into molds for 1/3 or 2/3 of the total volume. The process should take no longer than 20 minutes.
• Maintaining the mixture for 3 hours until complete gas formation.
• Removing from molds and cutting off excess with a jet-type cutting tool. If there is necessary equipment, groove elements are made.

Next, the autoclave steps are carried out, if appropriate units are available. When made at home, the products are stacked on wooden pallets and kept at an air temperature of + 20-24°C for several days. After that, they should be stored for 28-30 days at a humidity of not more than 60%. After this time, they are completely ready for use as a filler for rigid building frames or insulation.

Despite the fact that they are inferior to the factory ones in strength, the performance properties depend on the quality of the binder and its proportion in the composition.

Production nuances

In the manufacture of structural blocks, the main material is autoclaved aerated concrete. Pre-cut and prepared elements are placed in compartments where they are treated with hot steam under high pressure. Inside the autoclaves, a pressure of 10 atmospheres and a temperature of about 200 ° C are maintained, so it is impossible to achieve such parameters at home.

During processing, gas formation is completed due to the strengthening of the cellular structure. They also acquire the best strength, heat and sound insulation characteristics. After the production of aerated concrete in autoclaves, it has good frost resistance and resistance to moisture.

This technology significantly increases the cost of products, even if used equipment was used. Often it is of a stationary type, therefore it requires good foundation, as well as a special boiler that produces steam. Many manufacturers save on this and produce non-autoclaved products. In this case, it is used only as a heater; when erecting load-bearing walls of buildings or residential buildings, it is not recommended.

Overview of lines and production methods

For aerated concrete blocks, the following equipment is used, depending on the placement conditions and estimated volumes:

• Stationary lines - 10-60 m3 per day with the participation of a minimum number of employees.
• Conveyor - up to 150 m3, practical for large volumes.
• Mobile - for local production at home or construction site, powered by 220V.
• Mini-lines are automated and used for 15-16 m3 daily. They require a plot of up to 150 m2 and labor resources of up to 3 people.
• Mini-factory - similar to the line, but capable of producing a larger volume (20-25 m3).

The stationary system on the example of ASM-1MS is one of the most long-term and profitable. Mixing and filling of forms is carried out automatically, so all difficult steps do not require manual labor. A feature of this type is a mobile type mixer, complex equipment for preparing a solution, equipment for heating water, as well as a conveyor for supplying raw materials to the dispenser. Good productivity is considered an advantage, that is, the daily output is on average 40-60 m3. Such lines imply the presence of a large working area, they are quite expensive - more than 80,000 rubles.

Conveyor rooms also take up a lot of space, but the technology is somewhat different. Mixers and dispensers are not able to move, unlike molds. Considering the example of the German Inntech-100, it is worth noting that it is automated, but 6-8 people are needed for maintenance. The output capacity is 80-100 m3, and the cost is about 3 million rubles.

Mini-lines and factories can be stationary or conveyor type. In Russia, high-quality domestic equipment is produced from companies such as Inntehgrup, Altaistroymash, Kirovstroyindustriya. The set of MINI-1 lines includes: mixer, jet cutting machine, molds. Such an installation can be purchased at home, and does not require a large area. Need more space for drying and storage. The capacity is up to 60 m3 per month.

Mini plants are very practical for starting the process at home. But they differ from stationary complexes in that most of the steps are performed manually. According to the technology, workers themselves must carry out mixing of the solution, pouring into molds and cutting. 4-5 people are enough as attendants.

Mobile lines are distinguished by the ability to manufacture blocks in the place where it is needed, since the working area does not exceed 2-3 m2. Aerated concrete 500B plus includes a compressor, two-meter sleeves for the simultaneous filling of several forms and a mixer. 1-2 people are enough for work, energy consumption is no more than 1.5 kW per hour, and productivity reaches 25 m3, cost is 50-60 thousand rubles.

Aerated concrete production as a business is an excellent opportunity to start your own line of production of aerated concrete products. The above standard equipment does not include an autoclave. Automated installations with autoclave chambers are produced in China, their cost increases by more than 1 million rubles. Such a full-fledged complex should be purchased after contacts with customers have been established and recommended as a manufacturer of quality goods.

Autoclave blocks allow you to save time by eliminating the stage of natural drying on pallets. They reduce the need for electricity to maintain the optimum temperature of 22-23°C and room humidity up to 55-60%.

Contemporary low-rise construction houses today is experiencing a steady growth only thanks to the use of new materials, among which a special place is occupied by gas-filled concrete blocks. Therefore, it is not surprising that equipment for the production of aerated concrete blocks is no less popular than aerated concrete itself. To date, the demand of individual developers for relatively inexpensive material and simple technology make it possible to organize mini-production of aerated concrete blocks practically at home.

The specifics of the technology for the production of aerated concrete blocks

Like any other foam production scheme, the technology for the production of aerated concrete blocks is based on several relatively simple operations:

• Preparation of the matrix mass and gas-forming agent;
• Mixing the initial components on special equipment, obtaining concrete saturated with a large number of tiny bubbles;
• Stabilization of aerated concrete mixture and distribution of material into prepared forms;
• Hardening and maturation of finished aerated concrete blocks.

For your information! The basis for the production of aerated concrete mass with the help of a large amount of gas is the reaction of the interaction of powder or paste-like aluminum with water-saturated lime.

This method simplifies production, since powerful compressor equipment is not required to create a porous structure in aerated concrete. Therefore, a set of equipment for mini-production of aerated concrete blocks at home will cost less, and the technology itself allows you to get a more stable and uniform distribution of bubbles in the thickness of the aerated concrete block.

In production aerated concrete materials on mini plants, the formed blocks are sent for maturation or maturation for 28-30 days. During this time, the cement mass gains strength, part of the unbound water evaporates, and after the mandatory packaging of the blocks in a shrink film, the material is sent for sale.

For your information! If in the production of the closest competitor of aerated concrete - foam concrete block, freshly prepared foam blocks for another two or three months give out bad smell, then aerated concrete does not have such a disadvantage.

The industrial production of aerated concrete blocks involves the use of autoclave steaming chambers, which reduce the time to set the standard strength to 12-20 hours. What is the difference between a steamed block and a block made on a mini installation can be found in the video:

Technological equipment for the production of aerated concrete blocks

The set of equipment for a mini plant or line for the production of aerated concrete includes the following units:

1. Barrels for storing components and measuring devices for precise dosing of consumables - cement, sand and lime;
2. Container for producing aluminum slurry from a pasty agent;
3. Mixer or tank for mixing components with the formation of foamed gas-filled liquid concrete;
4. Forms for pouring and cutting a raw aerated concrete slab into blocks.

For the preparation of one cubic meter of aerated concrete, 90-100 kg of cement of the 500th grade, sand and lime in the amount of 370 kg and 35 kg, respectively, of purified water - 300 liters will be required.

The scheme of preparation of aerated concrete casting

Lime, cement, activator aluminum suspension, sand are sequentially loaded into the mixing tank and thoroughly mixed for 10-15 minutes. The concrete mixture, which resembles whipped cream in consistency, is pumped into a collapsible pouring mold made of thin sheet metal.

Due to the fact that the chemical reaction of gas formation does not stop with the pouring of the concrete mass into the molds, a “cap” is formed above the sides, which must be carefully cut off with a string cutter. After two hours, the cast slab can be cut into blocks, and the molds can be taken apart and prepared for new use. The sequence of operations in a technologically competent way can be found in the video:

Production of blocks for sale

The business of producing and selling aerated concrete looks quite attractive due to the simplicity of the technology and relatively low associated costs. Equipment for the production of aerated concrete blocks costing up to 200 thousand rubles and with a capacity of up to 10 cubes of a block per shift can fit within a room of 30 m 2. This means that, apart from the costs of purchasing, transporting raw materials and wages to workers, no other costs are foreseen.

From serial samples of equipment, simple manual installations of the Felix 10 type can be advised. Most operations for loading the mixer and forming blocks are performed manually, which means that the equipment is easy to set up and maintain. Production Line Information aerated concrete block shown in the video:

The average cost of raw materials and energy for the production of one cube of gas-filled concrete foam is 1400 rubles, which is 20% lower than the same indicator for foam concrete. The cost of labor of two workers with a total salary of 40,000 will be 1,500 rubles per day for the production of 10 cubic meters of the mixture, or 150 rubles per cubic meter of aerated concrete blocks.

With a wholesale price of 2,300 rubles per cubic meter of aerated concrete block, the profit will be 800 rubles, or 8,000 rubles a day. For 24 working days, this is 192 thousand rubles.

Price homemade equipment is 160 thousand rubles. Renting one set of industrial production "Antey 40" will cost 20 thousand rubles. This means that if within two months it is possible to produce and sell 480 cubic meters of aerated concrete blocks, then it will be possible to make a profit of 340 thousand rubles on rental equipment, excluding transportation, packaging and storage costs.

In reality, the main difficulty lies not in production, but in finding a buyer. A batch of 480 cubic meters of aerated concrete is sufficient for the construction of 5-6 one-story houses. Therefore, the main problem is not in production, but in the sale of manufactured products.

Will the aerated concrete block withstand competition from foam concrete

Before writing a business plan, it is worth considering the competition from foam concrete, which occupies the lion's share of the foam market. The opinions of various experts on how much one material is better or worse vary greatly. Often, assessment and comparison are made using personal impressions, as in the video:

Therefore, it is worth taking a closer look at the main characteristics of a competitor.

The data given in the table show that the cost of a foam concrete cube is at least a third less than aerated concrete blocks. In this case, the average value of the tensile strength of the foam is higher. Contrary to popular belief, aerated concrete and foam concrete equally conduct water vapor.

The main advantages of aerated concrete, which can become real engines of trade, are:

• The possibility of reinforcing masonry. Any serious buildings made of foam materials require reinforcement, so foam concrete is well suited for a bathhouse or garage, for a house - aerated concrete;
• High frost resistance. Open walls can be laid out of aerated concrete, and foam concrete will need to be additionally lined with plaster;

Mini-plant for the production of non-autoclaved aerated concrete

Previously, the manufacture of aerated concrete products was only in factories. Now equipment for the production of aerated concrete can be installed on small sites or even in the yard of your own house.

Depending on the number of required blocks, you can purchase equipment in the form of a mini-factory, install a mobile unit to produce blocks of various densities.

Aerated concrete production technology

Aerated concrete belongs to the category of cellular concrete. It consists of a mixture of several components:

• sand - 20-40%;
• lime - 1-5%;
• cement - 50-70%;
• clean water - 0.25-0.8%;
• aluminum powder - 0.04-0.09%.

Sand is used sifted, its fractions do not exceed 2.1 mm. Clay in it should contain no more than 7%. Cement needs high-quality - brand M400 or M500. Aluminum powder is used as a blowing agent. The composition may include some more components: plasticizers, hardening accelerators. To change the properties of gas blocks, slag, gypsum or sawdust are added to the mixture. These additives can change the density of the blocks. After all, the material for the manufacture of the foundation must be stronger than for the partitions. It is desirable to make heat-insulating blocks lighter and more porous. To do this, you can completely exclude sand from its composition.

The production of aerated concrete products can be autoclaved and non-autoclaved. The second option is much simpler, but has low strength, insufficient accuracy. geometric dimensions. Autoclave products are usually more homogeneous structure and low heat capacity. Such blocks are used in Russia for the construction of walls up to 400 mm thick.

Block making

For the production of gas blocks, particularly complex installations are not required. All that is needed is the precise execution of technological cycles. Production can be carried out in the following order:

• preparation of components;
• the introduction of a blowing agent;
• laying the solution in molds;
• cutting blocks;
• maturation of products;
• autoclaving.

All necessary components are weighed and poured into the mixer for mixing. After 10-15 minutes, aluminum powder is added to them, which immediately enters into a chemical reaction with the lime in the mixture. As a result of the reaction, the mixture is filled with gas in the form of bubbles throughout the volume. This is a signal to lay out the solution in molds for aerated concrete or on a special tray in a thick layer. On the tray, the mass is cut into blocks with special saws. Semi-finished blocks ripen within 10-18 hours. After that, the blocks are placed in an autoclave. This is a special oven, consisting of a sealed chamber with a temperature of 190°C. In it, the material is processed with hot steam under high pressure. Next, the finished material is removed from the autoclave and laid out to dry.

Non-autoclave building material is dried within 3-7 days in a natural way. Next, the blocks are stored in a room to gain full strength. This usually happens within 30 days. Only after this period it is possible to transport aerated concrete to the consumer, packing it in a special shrink film.

Block making equipment

For aerated concrete blocks, a production line is usually completed, consisting of:

• mixer;
• activator;
• dispenser;
• cutting device;
• autoclave;
• forms.

All this equipment comes in different capacities. It usually varies between 10-150 m³ per day. The most expensive part of this set is the autoclave. The cost of the finished product depends on it. At home, this production most often becomes unprofitable.

The equipment can be divided into the following types:

• fixed line;
• conveyor line;
• mini line;
• mini plant;
• mobile line.

A stationary line of equipment for aerated concrete can produce from 60 m³ of products per day. For its storage, approximately 500 m² of area is required. 2 people can manage the line quite well.

The conveyor line can produce 75-150 m³ of finished products per day. Placement of equipment for the production of aerated concrete blocks requires an area of ​​​​more than 600 m². It is served by 8 people.

The mini-line is designed for a daily output of about 15 m³ of products. The line includes a mixer and molds. To organize the production and installation of equipment, 2 people and 140-160 m² of area are required.

The installation of a mini-factory guarantees the production of finished blocks from 25 m³ per day. It's a little more than using a mini line. The mini-plant is distinguished only by the presence of pallets, a water tank, and equipment for cutting aerated concrete in its composition.

Mobile lines are often used in the construction of private homes. They allow you to reduce costs by a third. To obtain high-quality aerated concrete, the equipment is connected to a 220 V socket. The line may include:

• stationary mixer;
• mobile molds for pouring mortar;
• block cutting machine.

The line capacity reaches 100 m³ per day.

Conclusion on the topic

For thousands of years, people have been building houses for themselves. Over the years, technologies and materials for construction have changed significantly. In our time, construction using aerated concrete in the form of blocks has become relevant. Previously, blocks were produced only in factories, today their production can be set up at home. To do this, you need to have a desire, purchase equipment and install it all on a prepared site. For the release of aerated concrete, you need to have a clean warm water, quartz sand, aluminum powder of the PAP-1 brand, lime, Portland cement M400 or M500 and a few more additives to improve product quality. Having received all this, you can start your own business for the production of building materials that are in great demand. When building your own home, the material will cut costs by about a third.

For own production it is best to purchase a small stationary line with which you can make non-autoclaved aerated concrete. The unit can be operated by 2 people. With such forces, about 60 m³ of excellent blocks can be produced daily. Each such fake diamond weighs approximately 30 kg and replaces about 30 standard bricks. The gas block weighs several times lighter than a brick, therefore it does not require the construction of a capital foundation and the use of lifting equipment. The material is perfectly processed with hand tools: a saw, a chisel, a drill. Nowadays, aerated concrete occupies a leading place among other building materials.

The technology for the production of aerated concrete is simple, taking into account its demand, the launch of its own line for the production of blocks is considered to pay off. The standard complex includes crushers, a vibrating screen, batchers, mixers, conveyors, molds for pouring and a cutting machine; if you want to manufacture autoclaved gas blocks, a heat treatment unit is added to the scheme. The main criteria for choosing lines are productivity, floor space, the need for labor resources, energy consumption. The value of investments depends on the same factors, the minimum price of equipment without an autoclave is 400,000 rubles (without molds), a mini-factory is 2,400,000, when buying used machines, costs are reduced by 10-20%.

The basis is Portland cement with a grade of at least M400, filler, water, blowing agent and plasticizing additives. Various components can be used as inert ones: dolomite flour, ash, screenings of non-metallic rocks, lime, grinding of metallurgy waste, sand. Their share determines the porosity and density of products, in heat-insulating aerated concrete blocks it is minimal. To ensure the gas formation process, aluminum powder (PAP-1 or PAP-2) is in the highest demand - a powder with a layered structure, supplied in metal barrels. There are no special requirements for water, ordinary tap water or from an open source without large particles of sludge is suitable, the only condition is its heating (the optimum temperature is + 42 ° C).

Consumption depends on the purpose of aerated concrete blocks and their expected strength grade. On average, the production of 1 m3 takes:

The volume fraction of the binder from the total dry components reaches 60%, the filler - 40. Of these, 15% is sand, another 15 is limestone or dolomite flour, 10 is chopped and mixed in water cut off excess from products (the so-called pink salmon). Thanks to this, the production of aerated concrete blocks is waste-free. If there is doubt about the freshness and activity of the cement, the proportion of the blowing agent is increased by 200 g per 1 m3. The choice of filler material often depends on the availability of specific raw materials, each manufacturer of gas blocks has its own proportions. With overestimated requirements for strength or other characteristics, plasticizers are introduced into the composition; they are not necessary in conventional grades.

Features of aerated concrete production technology

The manufacturing process prior to autoclaving consists of the following steps:

• Preparation and dosing of all components except for the blowing agent and their thorough mixing in mixers for 5 minutes.
• Introduction of aluminum powder and final mixing - 1 min.
• Pouring the resulting liquid mixture into pre-prepared forms: from 1/3 to 2/3 of their volume. This step takes no more than 20 minutes.
• Exposure in forms: from 2 to 4 hours until the end of the process of gassing.
• Removing molds, trimming excess with strings cutting tools, in the presence of appropriate equipment - the implementation of slotted holes.

Further steps depend on the possibility of autoclaving. When produced at home (or close to them), the blocks are simply kept on pallets for at least two days at an ambient temperature of +20 ° C, then another 21-28 days at normal humidity. A month later, such products are ready for use, inferior in strength to factory ones, they are quite suitable as a heater or for filling the space between rigid frames. Their performance characteristics are directly dependent on the activity and proportion of the binder.

The main material for the manufacture of structural blocks is autoclaved aerated concrete. In this case, the cut blanks are placed in special chambers and treated with hot steam under high pressure. Approximate parameters of the environment inside the autoclave: +200 °C, not less than 10 atm, it is impossible to achieve them at home without the appropriate equipment. In the process of processing, the walls of the cells are strengthened and gas formation is successfully completed, as a result, the blocks improve their insulating and strength properties. Autoclaved aerated concrete withstands moisture loads better and has higher frost resistance.

This technology increases the cost of blocks even when buying second-hand heat treatment equipment: it is most often stationary, it needs a reliable foundation and a boiler to generate steam. In order to save money, many entrepreneurs first launch a line for the production of non-autoclave gas blocks, providing for the installation of an autoclave in the future. You can do without this stage when molding products intended for thermal insulation.

Overview of lines and methods for the production of gas blocks

Depending on the volume of products and placement conditions, all equipment for the production of aerated concrete blocks can be divided into the following categories:

• Stationary lines used to produce from 10 to 60 m3 blocks per day with minimal involvement of human resources (1-2 workers).
• Conveyor - producing up to 150 m3, optimal if it is necessary to provide large volumes.
• Mobile equipment - for the manufacture of gas blocks with their own hands directly on the construction site or at home, powered by 220 V.
• Mini-line is an automated complex for high-quality gas blocks with a volume of up to 15 m3 per day with compact placement (occupies no more than 150 m2) and maintenance by 3 people.
• Mini-plant - a similar line, but winning in terms of power, up to 25 m3 of aerated concrete is produced per day.

Stationary equipment is considered the most profitable in the long run, thanks to automated form filling, it works almost independently, manual labor is excluded at difficult stages. characteristic feature These lines are the presence of a mobile mixer, a complex for the preparation and storage of raw materials, water heating and conveyor supply to the dispenser. Their advantage is a significant production capacity (without heat treatment - up to 60 m3 of gas blocks), a minus - the need for large areas (up to 500 m2) and the high cost of machines and installations (from 900,000 rubles and more, it is more difficult to buy it used).

Conveyor lines also take up a lot of space (from 600 m2), but they implement a different production technology: the aerated concrete dispenser and mixer remain stationary, while the molds move. The process of such a complex is also fully automated, but due to the increased volumes of products, maintenance is not recommended to be carried out by yourself, 4-8 people will be required. It costs more than others, the minimum price of conveyor systems with a capacity of 100 m3 / day is 3,000,000 rubles.

The main advantage of mobile equipment is the ability to produce aerated concrete in any convenient place, including at home, it occupies only 2 m2. The standard kit includes a compact mixer, a compressor and connecting sleeves about 2 m long (for filling several forms at once). Mobile installations cost no more than 60,000 rubles, and consume no more than 1.5 kW per hour (for example, Aerated concrete-500 B plus), in order to save money, you can buy them second-hand. For the manufacture of gas blocks at home with their use, the forces of 1 person are enough, but when 2 are involved, the work will go faster.

Mini-lines and factories for the production of aerated concrete blocks are both stationary and conveyor. They are offered to buy a number of domestic factories, good feedback have Inntehgroup and Kirovstroyindustriya, the best include the production lines of Altaistroymash. The combination of mini-lines can be different, but the main equipment (a mixer, molds and a machine for cutting gas blocks) is always included in them, this is enough to start production even at home. The devices themselves will take up little space (depending on power - from 10 to 150 m2), but one should not forget about organizing a platform for drying gas blocks.

Mini-factories are optimal if you need to make gas blocks with your own hands for sale, they can be used as a launch pad. The main difference from automated stationary and conveyor lines is the need for manual labor in such labor-intensive technology processes as preparing components, pouring molds and cutting. At least 3-4 people will be needed for service.

Almost all the proposed lines of domestic production do not include autoclaves in the standard package. Automated mini-factories with them are sold by China, the cost of equipment will increase by at least 1,000,000 rubles. The acquisition of an industrial autoclave is advisable with an already established sales line or if you want to squeeze out competitors. With the inevitable increase in energy consumption, their installation allows to reduce the cycle time (there is no need to dry the aerated concrete blocks on pallets for 3 days). Almost all modern autoclaves are automated, including the supply of products to the oven and unloading.