How to make aerated concrete with their own hands? Stages of work to make the building material at home
Calculating the budget for construction, many builders begin to look for options to save money, one of which may be an attempt to make their own construction material. However, not always home production is cost-effective, because for the organization of mini-production, in any case requires the presence of at least a minimum set of equipment and basic raw materials.
In this article, we will examine how reasonable it can be to manufacture products intended for the construction of walls. So, aerated concrete with their own hands at home: is it possible, and how profitable?
What is aerated concrete and what are its characteristics
Before understanding how to produce aerated concrete in the home, should first consider what is this material. What qualities does it have and whether it is worth it to stop your choice at all?
Basic properties and qualities
Aerated concrete, in accordance with GOST, must have a number of characteristics, the indicators of which are strictly limited. Let’s consider them, and analyze: how important and practical they are for the future construction. We will use the table.
Physical, mechanical and technical properties of aerated concrete:
| Name of parameter | Value according to GOST |
| Thermal conductivity | From 0.09 to 0.38 |
| Frost resistance | From 15 to 35 cycles. for non-autoclave aerated concrete, from 35 to 150 cycles. for autoclave aerated concrete |
| Density | D300. D1200 |
| Strength grade | From B1,5 for non-autoclaved aerated concrete, from 2,5. for autoclaved |
| Vapor permeability | On average. 0.2 |
| Shrinkage | From 0,3 mm / m2 |
To begin with, let’s pay attention to the thermal conductivity. According to the technical documentation, it varies from 0.09 to 0.38. But, in practice, in operating conditions, its numerical value will be higher, as the above is typical for products in dry condition.
Thermal conductivity of aerated concrete and wall thickness in comparison with other materials for walls
- The moisture content of aerated concrete varies from 25-30%.
- Frost resistance indicates how many freeze-thaw cycles the products can withstand. Some manufacturers claim that this figure for aerated concrete can reach 150, and the service life. up to 200 years.
- The density may be different, it depends on the porosity of the block and some other factors. This indicator determines the scope of the material, we will talk more about it later.
- Vapor permeability. the material’s ability to vapor exchange. For example, if humidity. increased, aerated concrete is able to absorb it, and if excessive dryness, it. to give. Thanks to this quality, the most favorable microclimate will be established in the room.
- Shrinkage. a rather unpleasant phenomenon. However, the figure of 0.3 mm/m2 is not that high. The appearance of cracks during shrinkage. a common phenomenon.
Material types and products from it
Now let’s consider what types of material there are, and what products can be obtained, starting the production of aerated concrete at home.
Depending on the density, aerated concrete is:
The first variant is characterized by a density of 300-400. It is lightweight and has a minimal thermal conductivity coefficient. And even the name speaks for itself: this aerated concrete is used as a heat insulating material.
The constructional-thermal insulating type is the most popular type. Its density varies from 400 to 900. It is used in the construction of walls and partitions.
Structural. the most durable kind. Its density is 1000-1200. However, the thermal conductivity coefficient is also high, which provides for additional heat insulation of the material. Products can withstand serious loads, are used in the construction of buildings up to 12-15 meters high.
The conclusion is obvious: the higher the density, the higher the heat transfer coefficient. Let’s consider with the help of a table, how these indicators change mutually.
Dependence of density and thermal conductivity of aerated concrete:
| Type of aerated concrete | Density | Thermal conductivity in dry state |
| Thermal insulation | Д300 | 0,09 |
| Д400 | 0,11-0,12 | |
| Structural and thermal insulation | Д500 | 0,12-0,13 |
| Д600 | 0,13-0,14 | |
| Д700 | 0,15-0,18 | |
| Д800 | 0,18-0,21 | |
| Д900 | 0,20-0,24 | |
| Structural | Д1000 | 0,23-0,29 |
| Д1100 | 0,29-0,34 | |
| Д1200 | 0,29-0,38 |
The graph of strength and thermal conductivity of aerated concrete
However, this is not the only classification. According to the way of hardening, gas concrete is autoclaved and non-autoclaved.
Autoclaved aerated concrete, or synthesis aerated concrete, is distinguished by the fact that in the final stage of production the products are processed in special machines. autoclaves under the action of high pressure and temperature.
Non-autoclaved aerated concrete, or aircrete of hydration curing reaches technical maturity in natural conditions. Sometimes it is slightly heated to a low temperature, not exceeding 100 degrees in order to accelerate the process.
Pay attention! Autoclaved curing blocks can be made only in factory conditions.
GOST 21520-89 Cellular concrete wall blocks. Technical specifications provide for separation of products according to their geometry.
Depending on the category of accuracy, there are gas blocks:
- The first category of precision. Admissible dimensional deviations of such blocks must be not more than 1.5 mm, diagonally. not more than 2. The products are laid on the glue.
- The second category of accuracy. For such products, there are more significant deviations: up to 3 mm in size, and up to 4 mm. to the diagonal. Chipping on corners is also allowed. Paving is performed either with adhesive or mortar.
- The third accuracy category. Such products are laid on the mortar, which will undoubtedly lead to an increase in thermal bridges. Consequently, these aerated concrete blocks are usually used in the construction of outbuildings in the form of a garage or barn. Tolerances: up to 5 mm. in size, up to 10 mm. chips in the corners (no more than two in one product).
Also, aerated concrete is divided depending on the type of binder component:
The type of silica component determines the presence in the composition:
The strengths of buildings built with aerated concrete
Aerated concrete is not a universal material due to the presence of positive and negative sides.
Aerated concrete with their own hands save construction budget
Is it possible to make aerated concrete with your own hands? This question is often asked in online forums today. The thing is that suburban developers, who gave preference to this particular building material, want to save a little. By the way, the independent production of aerated concrete reduces its cost by 30%.
What is aerated concrete?
This is one of the varieties of porous cellular concrete. To ensure that the quality was high, in the process of making aerated concrete at home it is necessary to achieve a uniform pore distribution throughout the entire volume of the material.
Currently, there are two ways of its production: autoclave and non-autoclave. In our case we choose the second option. It, firstly, does not require the use of special equipment. Secondly, it is simpler.
For the production of aerated concrete non-autoclave method requires the use of four basic materials: cement, sand (can be replaced with slag or ash), lime (added in small quantities), aluminum powder.
Comparison of independent and factory-made products
In the manufacture of aerated concrete blocks with their own hands, they harden by hydration, and in production. autoclave. These materials differ from each other in technical and physical parameters. In the manufacture of blocks are made by stationary and conveyor method. With the second option reduces the need for human involvement to a minimum. Man is continuously and directly involved in the home production of this material.
Compared to autoclaved aerated concrete, homemade blocks are less strong. Also factory material has better indicators of frost resistance, brittleness, thermal conductivity.
Mixture preparation
Gas concrete composition.
Standard aerated concrete mix contains cement, sand, water and lime. Aluminum powder is used as the substance that forms pores. Quicklime acts as a softener. To improve the properties it is recommended to use additional additives: sodium sulfate (no more than 0.5%) and caustic soda (not more than 1.5% by weight).
The basis of aerated concrete is cement. It is recommended to use Portland cement M400 or M500. The filler is taken in the form of quartz sand. It should be carefully sifted to remove large fractions. Clay in the sand may be only in the form of small traces and is no more than 7% of the weight of the sand. The following composition and ratio of ingredients of the concrete mixture are recommended:
The mixture must be thoroughly mixed. By changing the content of cement and pore-forming composition, it is possible to regulate the pore volume in concrete, i.e. to change the density of the material.
Step by step instruction of the process
Gas concrete blocks are made by two main methods. autoclave and non-autoclave. The first method is used for industrial production, and the second method is suitable for domestic work, as the material poured into the mold dries in natural conditions.
The general technology of preparing aerated concrete products consists of the following steps:
- Purchase and preparation of materials, tools and equipment.
- Formation of the composition (kneading the future poured).
- Spreading the concrete mixture into the molds, lubricated with a special agent.
- Steam curing (autoclave curing).
- Drying of the mixture in a natural environment (non-autoclave curing).
- Picking up aerated concrete from removable mold.
- Laying for airing on a prepared surface.
- Packaging in polyethylene, for further transport.
It is desirable to leave the dried ready products for 3-4 weeks. So the resulting product will gain more strength and density, and only then it can be used in construction. The process of creating aerated concrete with their own hands is time consuming, takes a long time compared to the industrial, and requires constant human involvement from the beginning of the work, and to the end.
Important! For greasing the forms in domestic construction, you can use machine oil (even used), for this purpose it can be diluted with water in a concentration of 1:3. Depending on the mold used, large blocks are cut into desired sizes.
With improvised means and mechanisms
When you do your own handiwork, the focus is on the removable form. Large block shapes can be cut to size, which can be purchased in building stores or hired from the building contractor. The form should have 2 constituent parts. the tray and the sides, which are lubricated before pouring the mortar with a special agent. Trays are made of either moisture-resistant plywood or stainless steel.
For home use, molds can be standardized to certain sizes. Before pouring and general preparation for the process:
dry components of the future mortar are mixed in a container and poured with water using a construction mixer or shovel;
When performing domestic work, you must follow safety precautions, and work in special protective clothing and gloves.
Important! The room in which the work process will take place should be ventilated and ventilated, but without drafts. The recommended temperature for the work should not be less than 20 ° C.
On the conveyor equipment
On industrial lines the creation of aerated concrete products is carried out as follows:
- In the concrete mixer is poured clean water, the temperature of which should be 40-60 ° C.
- Then the mixer is automatically turned on and dry substances are poured. first the cement, and then all the other components, except for gas formers, which are mixed for 5 minutes.
- At the end of the mixing process the aluminum powder is added and the mixture is kneaded for another 30 seconds.
- The mold is prepared. it is assembled and lubricated, the concrete mortar is poured from the switched-off mixer into it, evenly distributed over the entire inner surface.
- The form with the composition is placed in the chamber for heating and structural strength development (up to 3 hours).
- Then the form is rolled out, and the cutter cuts the top, cutting the mass into pieces (blocks of desired shape).
- The resulting aerated concrete products are placed in an autoclave (50-60 ° C) for up to 8 hours, for final curing and hardening, remove the formwork.
- After that ready blocks are placed on a pallet, aired, packed and sent to a warehouse or an adapted place for storage.
The industrial conveyor belt is the fastest and most efficient way to create aerated concrete, but the purchase of professional equipment requires a large cash investment (from 5,000,000) and is only worthwhile if you want to do business in large quantities, if you have or are looking for a good market. It is not suitable for home production, as it requires a large area for production.
Important! Compared to the factory, homemade gas blocks will be less durable, as the autoclave method allows you to create a more durable industrial product, with good indicators of frost resistance, thermal conductivity and density.
Stationary
The creation of aerated concrete by this type of equipment on the stages is identical to the conveyor, the only difference is that the belt is a reduced copy of a large industrial, and the entire process takes place in series, with the advancement of the poured mold on the rails along the equipment. Also this method requires less investment and space for production facilities. The stationary method is more recommended for entrepreneurs, but not for home use.
The stationary method allows you to create professional products from non-autoclaved aerated concrete. Here all the equipment used is autonomous and does not require manual labor, but must be placed in a special room.
- On this belt, the dry mortar is sifted through a vibrating screen, measured with automatic batchers, and mixed with a mobile mixer.
- The heating of the water for the mortar to 40 ° C is held in special boilers and controlled by temperature regulators.
- The mould is lubricated and the mixture is poured into it and allowed to set. The temperature in the room is maintained at no less than 20 ° C, so within 5 hours the product will be ready.
- Then the resulting non-autoclave product is removed, aired and placed on a pallet, for further acquisition of strength properties within 1 month.
On a mobile mini line
Work on the mini-production is characterized by mobility, and is suitable for the initial process of entrepreneurship, as it takes a small area of the room, and requires minimal investment compared with the professional industrial production of stationary and conveyor types. When using such a line, the steps will be as follows:
information
Aerated concrete blocks can be made in a variety of configurations, changing the size of forms and their design depending on what kind of masonry is planned. It can be attributed to the important advantages of the production of this building material. Of course, in terms of strength characteristics produced non-autoclave method aerated concrete will be somewhat inferior to the autoclave. However, for personal use in carrying out not too large-scale construction, it will fit perfectly.
Different strengths for concrete mortar can be achieved by changing the proportions of the components. However, the standard formulation will correspond to the following indicators:
Comparison of autoclaved and prefabricated products
In the production of aerated concrete blocks with their own hands they are hardened by hydration, and in the production. by autoclaving. These materials differ from each other in technical and physical parameters. The blocks are produced in a stationary or conveyorized manner. With the second option, the need for human participation is reduced to a minimum. In domestic production of the material man is constantly and directly involved.
Compared with autoclaved aerated concrete, homemade blocks are less strong. Also factory material has better indicators of frost resistance, brittleness, thermal conductivity.
Comparison of self-manufactured and prefabricated products
In the production of aerated concrete blocks with their own hands they harden by hydration, and in the factory. autoclave. These materials differ from each other in technical and physical parameters. The blocks are produced by stationary and conveyor method. With the second option, the need for human involvement is reduced to a minimum. In the home production of the material man is constantly and directly involved.
Compared to autoclaved aerated concrete, home blocks are less durable. Also the factory material has better indicators of frost resistance, brittleness, thermal conductivity.
How to use in practice?
To build a house or building in a short period of time using modern materials is real. Experts in the category of construction work note that aerated concrete is an affordable and high-quality material by all standards, which is used for:
- residential buildings;
- auxiliary household premises;
- garages;
- storage space;
- stores;
- Buildings for private businesses.
How to make the right choice?
So, the decision is made. the walls of the planned construction will be of aerated concrete, determine what is more profitable:
- We calculate the total cost of material and make the purchase.
- Make a weighted decision to buy everything you need and set up the production of aerated concrete with your own hands.
To find a reliable partner who offers a quality product, you can use the services of our website. It is possible to purchase the necessary materials and equipment for the beginning of work within a day, without fussy shopping. The right composition and endurance of the technological process, will bring the long-awaited fruit. Setting up a mini-business producing aerated concrete or your own needs is a pleasant job with obvious results.
5 / 5 ( 1 vote )
On the site: author and editor of articles on the site pobetony.ru Education and work experience: Higher technical education. Experience in various productions and construction sites. 12 years, including 8 years abroad. Other skills: Group 4 electrical safety clearance. Perform calculations using large amounts of data. Current Employment: Serves as an independent consultant to a number of construction companies for the past 4 years.
Profitability of production
On the profitability of the blocks affect a variety of factors. It depends on:
- The cost of raw materials;
- The investment for the purchase of equipment;
- The amount of production waste;
- The desired volume;
- The purpose of production.
Experts have made calculations in accordance with the indicators, according to which it was found that it is more expensive to make aerated concrete blocks with your own hands than to buy ready-made material. In addition, the process requires effort and time.
Aerated concrete blocks. a versatile building material, which is widely used in the construction of buildings. It can be purchased at factories and construction stores. It is also possible to make blocks with your own hands, preliminarily calculating the profitability of this process.
Making aerated concrete with their own hands
The production of aerated concrete at home requires some tools. Must be prepared:
- angle grinder with a disc;
- wood hacksaw;
- electric drill;
- planer;
- hacksaw for working on metal;
- sharp knife;
- a locksmith’s hammer;
- mortar shovel;
- a mixer for mixing the mixture;
- ruler;
- construction dryer;
- trowel,
- A steel string to cut the blocks;
- trowel;
- scales;
- a chisel and chisel;
- measuring bucket.
Using a measuring bucket and scales, measure the necessary components for the mortar. Production of gas blocks is carried out with the following components:
- Portland cement M400-M500. 50-70%;
- sifted silica sand. from 20 to 40%;
- lime as a plasticizer. 1-5%;
- powder or aluminum paste. 0.04-0.09%;
- water. 0,25-0,8%.
The mixture is thoroughly mixed and placed into molds, which come in a variety of shapes. This can be a pretty sturdy box. Its height is equal to the height of the blocks. Total volume. 4-9 gas blocks. The molds can be made of wood or metal. It is desirable to make a collapsible structure. A more complex variant. a box with cells, which can be made of wood 30-40 mm thick, or metal 4-6 mm. Internal partitions can be made of plywood. Its thickness should be 12-15 mm. Before pouring the mortar, the inside surfaces should be lubricated with technical oil and heated to 40˚C throughout the construction with a hairdryer. The mortar is poured up to the level of half of the box height. The rest of the space will be filled with the expansion of the mixture and the formation of pores.
The reaction of gas release lasts 6-8 minutes. Lift the mortar first, and then set it down slightly. After shrinkage, you can cut the upper part with a prepared string, and remove the blocks from the mold. Cooling of the blocks must take place in natural conditions. The use of fans is not recommended. It is recommended to install the mold on a flat, horizontal surface. It is better to prepare several boxes at once in order to mix a significant amount of mortar. The working area must be sheltered from wind and precipitations. The block sizes can be chosen at your discretion.
Partitioning made of gas silicate
Gas silicate blocks are good for partitions, they are easy to install and it is not difficult to make a partition from gas silicate yourself. But, it is in words. put glue on, put the block, and look at the level. In practice, the nuances pop up quite a lot, and if you’re doing it for the first time, you are sure to get a little crooked. Irregularities can be repaired, sharpened or hidden by a layer of plaster, because gas silicate is a pliable material.
Gas silicate blocks with dimensions 600x100x250 are used for laying partitions. You can use gas silicate or other cellular concrete blocks thinner, for example 75 mm.
The construction of the partition wall of cellular concrete
The main thing in masonry partitions. observance of the vertical and horizontal plane. If you do not check each block with a level, you may not get a partition but a sculpture in the style of geometric abstractionism.
The walls must be fixed to the supporting walls with metal fittings 6-10 mm in diameter, at least 15-20 cm long, every 2-4 blocks the height. At the height of the wall, for example 2.5 meters should be at least 2 such embedded. One half of the rebar is inserted or hammered into the drilled hole in the wall, fixed with glue (the same as for blocks) if necessary, that is, if the diameter of the hole is larger than the diameter of the rebar. The second half is fixed in the joint between the blocks. To lay the reinforcement between the blocks in the blocks need to make small notches for it.
Making aerated concrete at home
Before you begin, the inner surface of the form should be thoroughly lubricated with machine oil to prevent the mass from sticking. It is recommended that the mold be heated to a temperature of about 40 degrees Celsius. Aluminum powder is injected into the evenly mixed concrete mortar and poured into a mold.
It is necessary to pour it on a height, approximately equal to half of the flange height of the box, which takes into account the expansion of the mass during the chemical reaction with the formation of pores.
A violent reaction with the release of gas occurs within 6-8 minutes. During this time, there is an active growth of the mass level in the mold. At the end of the reaction, the expansion of the mortar stops, and then a small shrinkage of the mortar occurs. After the cessation of vertical movement of the level with a strong steel wire cut off from the surface of the material all the irregularities (bumps, pocks). Thermal insulation material: asbestos, polystyrene foam, etc., is put on top of the pared-down block blank. д. The form is closed with a lid on top.
Natural drying of the gas concrete blocks takes place. Minimum drying time. 2 hours. After that the monolith can be cut into blocks of desired size. Recommended time before transportation to the storage site is 24 hours. Avoid draughts during ironing. Using a fan is not recommended. The cooling of the stock should be slow and even.