Aerated concrete blocks for DIY construction. Do-it-yourself aerated concrete blocks: step by step Do-it-yourself form for aerated concrete blocks

Building your own house or any nearby structures is always a necessary and interesting process that takes a lot of effort, time and money. Therefore, almost all building materials people have become accustomed to do with their own hands. At different times, the complexity of the work either increases or decreases, but in the 21st century, such a process has acquired new forms, because. Do-it-yourself production of gas silicate blocks began.

Main aspects of activity

Before you start making gas silicate blocks, it is necessary to know many features of production.

The most important thing is the variability of the production process, because different compositions can be used, depending on the technological process.

So, sand with cement can be used as the main reagents, but an option is also possible with a combination of ash-cement. Water and copper shavings remain unchanged, because. water serves to liquefy and adhere elements, and aluminum chips react, which contributes to the formation of pores.

In industry, an autoclaving element is used, but this is not possible with manual work, and therefore the activity is slightly re-profiled.

It is necessary to make a mixture that does not require steaming for maximum strength development.

There are many ways to cut aerated concrete, but it is better to immediately fill in the desired shape, because. at home, extra body movements will take too much time.

Usually saws and cutters for wood are used, because. they make a perfect cut in no time, but you can use a jigsaw to shape it.

The design is very light, so you can use a reinforcing rod no thicker than 6 mm. It can be bent immediately in the form of a frame, or you can make just one crate, depending on the required final strength, as well as the thickness of the product.

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Main job option

Here we will use a standard sand- cement mixture, but the volume of the solution will be given as a test, in order to know exactly what will happen in the end. You will need the following tools and materials:

• containers for materials;
• mixing containers;
• nozzle for solutions on a drill;
• cement m500 - 1900 g;
• hot water - 1400 ml;
• fine quartz sand - 1900 gr;
• aluminum shavings - 3 gr;
• washing powder - 0.3 gr;
• NaCl - 19 g;
• plasticizer - 19 ml;
• rubber gloves;
• respirator;
• forms;
• machine oil.

At the very beginning of the manufacturing process of gas silicate blocks, a gas-forming mixture is prepared. To do this, aluminum shavings, washing powder and a little water are mixed in a small container. You need to stir directionally for 3 minutes, while you need to be attentive to the chips, because. strong dust can rise from it.

Washing powder serves to degrease the chips, but in fact it will not bring any negative. All work is done with gloves and a respirator, so as not to inflict any injury on yourself.

In the meantime, the suspension is infused, you can start making the solution. To do this, sand is poured into a container, and a dry cement mixture is poured on top. The resulting dry mixture is mixed thoroughly so that in the end there are no lumps and inhomogeneous places. For mixing with a drill, it usually takes no more than 2-3 minutes, but in small volumes, even 1 minute is enough.

Water is poured into the dry mixture, and 200 ml should be left in the jar. A plasticizer is poured into the water in a jar and sodium chloride is poured out. The resulting consistency is mixed, but without fanaticism, as was the case with chips. It is enough to chat for 20-25 seconds, then move it aside.

The sand-cement mixture, already filled with water, is mixed for several minutes until a homogeneous mass. This will take a little longer than for the pre-dry mixture, because. you need to soak the solution completely. If the dry mixture is poured into water, then the solution will turn out with lumps, so you need to follow this step especially carefully.

Now dilute water can be added to the mixture, as well as aluminum slurry. The solution is mixed in the most thorough way until the silvery film disappears from the surface (no more than 2-3 minutes). The result is a fairly liquefied mass.

As a trial form, you can use any containers lubricated with machine oil or mining (as an option - plastic wrap). The solution is poured to 50% of the total volume of the container, because the rest will come on its own.

Aerated concrete is fake diamond, which is used for the construction of walls in individual construction. It is suitable for building load-bearing structures, internal partitions and filling interframe spaces. Gas blocks do not give a large load on the foundation, because they have a cellular structure and low weight. It is an economical building material with high thermal insulation properties.

There are several types of classification of cellular concrete: depending on the purpose, form, production technology and composition.

1. According to the processing method, autoclaved and non-autoclaved aerated concrete are distinguished.

2. According to the purpose, gas blocks can be heat-insulating, structural or structural-heat-insulating. They have a certain marking, for example, aerated concrete d500 belongs to the class of structural and heat-insulating blocks.

3. According to the form factor, they are divided into U-shaped, straight and tongue-and-groove.

Gas blocks are made from sand, cement, lime, water, gypsum and aluminum powder. Also, secondary and by-product industrial materials, such as slag and ash, can be used in production. Depending on the composition of aerated concrete, it is classified into:

• cement;
• slag;
• lime;
• ash;
• mixed.

The building mixture is converted into an artificially synthesized stone only under certain conditions. To obtain it, the technology of autoclave hardening is used. In this case, the composition solidifies under the influence of saturated steam and high pressure, changing its structure. The mineral tobermorite is formed in the mixture, which gives the material strength. Thus, autoclaved aerated concrete is obtained.

Concrete that hardens naturally is called non-autoclave. It has a cellular structure, but differs in its properties from gas blocks made using a special technology. This building material is more prone to shrinkage during operation, so it is advisable to use it in case of small loads. To increase the strength characteristics of non-autoclaved blocks, various reinforcing substances and fillers are added to the initial composition. Reducing shrinkage deformation allows the use of polyamide plastics for reinforcement.

The production of non-autoclaved blocks does not require expensive equipment, so you can make them yourself.

Do-it-yourself aerated concrete

The production process consists of several stages:

• selection and mixing of components;
• filling forms with a solution;
• exposure of the composition for strength gain;
• extraction from forms.

The universal composition for the production of aerated concrete contains cement, sand, lime, aluminum powder. The initial additives and their proportions may vary, depending on the availability of raw materials and the requirements for the finished building material. For example, in autoclave production, sand is sometimes replaced with ash or slag. And to obtain a building material with a lower density, it is possible to make aerated concrete based on TPP resins.

In the manufacture of aerated concrete at home, it is necessary to correctly calculate the ratio Supplies and take into account the features of laying and measurement errors. But there are also standard mixture recipes for gas blocks, in which the following proportions are indicated:

• Cement - 50-70%;
• Water - 0.25-0.8%;
• Gasifier - 0.04-0.09%;
• Lime - 1-5%;
• Sand - 20-40%.

These substances are also used in autoclave production. Focusing on the ratio given in the recipe, you can calculate the approximate number of components that will be included in the composition per 1 m3 of aerated concrete:

• Portland cement - 90 kg;
• Water - 300 l;
• Gasifier - 0.5 kg;
• Lime - 35 kg;
• Sand - 375 kg.

However, the ideal composition at home can only be achieved empirically, since much depends on the quality of the original components. Both the temperature of the water and the brand of cement can affect the course of a chemical reaction.

Instructions for self-production non-autoclaved aerated concrete

To obtain a gas block at home, complex equipment and tools are not required. The main thing is to clearly follow the points below walkthrough and use the components in a certain ratio, and not "by eye".

1. Based on the indicated proportions, calculate required amount ingredients.

2. First of all, it is necessary to mix Portland cement with pre-sifted sand.

3. Pour water into the resulting mixture and mix everything thoroughly.

4. Add other components to the solution. Aluminum powder is added last. In the preparation of both non-autoclaved and autoclaved aerated concrete, the process of mixing the ingredients is equally important. For even distribution of air bubbles, it is better to use a concrete mixer.

5. The resulting solution is poured into special molds, which are made of metal sheets or wooden planks. To make it easier to get the frozen aerated concrete, it is better to use collapsible structures. In addition, the form is recommended to be lubricated with engine oil diluted with water.

6. You need to fill the mixture in half, since it expands almost twice during the chemical reaction. This process takes about six hours, after which you can level the blocks by cutting off the protruding mass.

Formation in this case lasts longer than for autoclaved aerated concrete - it takes at least 12 hours for the mixture to harden. To speed up the process of solidification of the composition, it is recommended to add soluble sodium compounds (soda) at the stage of preparing the solution. The branded strength of the material is gaining after 28 days of exposure. Ready non-autoclaved gas block, prepared with your own hands, is suitable for low-rise construction, for example, for building a one-story house or garage.

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 only on the positive side, if low buildings (up to four floors) are being built.

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. The sand must be screened out before maximum size in 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 from cellular concrete. What are its features and what is this building material in general.

Aerated concrete was invented a long time ago, but with the development of new modern production technologies, improved aerated concrete blocks of various designs and types began to be produced. 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 at 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 automated production which requires minimal human presence.

Special equipment helps storage and transportation, and automatic dispensers measure out the required amount of components themselves. 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 of 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. Withdrawal is carried out 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 delivering finished products.

The installation also includes:

• Electrical engine;
• Filling hose;
• A CD with a complete description of 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.

Comments:

You can even reduce the cost of building your own house or cottage if you make aerated concrete with your own hands. have long become an indispensable building material for the quick and inexpensive construction of various buildings.

The composition of aerated concrete blocks includes: cement, lime, quartz sand, gypsum stone, aluminum powder and water.

There is nothing complicated in the manufacturing technology of non-autoclaved porous concrete. The composition includes available and widely used materials, and the maturation conditions of the composition are normal. All this suggests that making aerated concrete with your own hands is real.

Features of aerated concrete

Aerated concrete blocks are regular parallelepipeds of porous concrete. The material itself is a kind of cement-based concrete, in which air pores up to 3 mm in size are evenly distributed. Aluminum powder or paste is commonly used as a pore forming additive. In general, the concrete mixture has the following composition: cement, sand, aluminum powder, water, and various additives.

According to the manufacturing method, aerated concrete is divided into autoclaved and non-autoclaved. The first type of material is obtained in an autoclave at elevated pressure and temperature, which is realized only in industrial environment, providing proper process control in extreme conditions.

The non-autoclave manufacturing method is implemented in natural conditions, which allows you to use it yourself. The production technology is based on the fact that when aluminum powder comes into contact with water, a violent reaction occurs with the release of carbon dioxide. If this process occurs in a closed form inside a viscous mass, then gases form pores in the volume of this material. Even after the gases leave the mixture, the pores remain in the thickness of the mixture. After the mass has hardened under normal atmospheric conditions, aerated concrete is obtained, that is, concrete with closed pores in a shape close to round, with a diameter of 1-3 mm.

The porous structure provides the main advantages of the material, namely high thermal insulation properties combined with a low specific gravity with a sufficiently high compressive strength. Aerated concrete blocks have a density of 300 to 1200 kg / m³, depending on the amount of pore-forming substance introduced.

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Manufacturing features

The technology for obtaining non-autoclaved aerated concrete includes several mandatory steps and conditions. The pore-forming component is added to the cement-sand mixture and is evenly distributed throughout the volume. The process of pore formation occurs quite actively with the expansion of the volume upon contact of the powder with water.

To keep the pores inside the mass, the gas evolution reaction must proceed in forms having sufficient strength. The internal cavity of the mold sets the dimensions of the resulting block of aerated concrete. For the initial hardening of the mass, at least 2 hours are required. After that, the concrete can be removed from the mold, but must be in a stationary state on the racks until it is completely cured. The final strength value is reached only after 28 days of block drying. For the manufacture of aerated concrete with your own hands, it is necessary to ensure that the basic conditions are met and to carry out a number of necessary works.

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Required Tools

To make aerated concrete blocks with your own hands, you will need the following tools:

• Bulgarian;
• hacksaw;
• plane;
• electric drill;
• hacksaw for metal;
• hammer;
• shovel;
• mixer;
• ruler;
• building hair dryer;
• Master OK;
• putty knife;
• steel string;
• chisel;
• chisel;
• scales;
• measuring bucket.

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Preparing the mixture

A standard mix for aerated concrete contains cement, sand, water and lime. Aluminum powder is used as a pore-forming agent. Slaked lime acts as a plasticizer. To improve the properties, it is recommended to use additional additives: sodium sulfate (no more than 0.5%) and caustic soda (no more than 1.5% by weight).

The basis of aerated concrete is cement. It is recommended to use Portland cement grade M400 or M500. The filler is taken in the form of quartz sand. It should be carefully sieved to remove large fractions. Clay in the sand can only be in the form of small traces and amount to no more than 7% of the weight of the sand. The following composition and ratio of concrete mix ingredients are recommended:

• cement - 50-70%;
• sand - 20-40%;
• lime, caustic soda, sodium sulfate - 1-5%;
• aluminum powder - 0.04-0.09%;
• water - 0.25-0.8%.

The mixture must be thoroughly mixed. By changing the content of cement and the pore-forming composition, it is possible to control the volume of pores in concrete, that is, to change the density of the material.

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Making a mold

In order to solve the question of how to make aerated concrete, it is necessary to ensure the manufacture of a mold for pouring concrete mixture. Such forms can be of two types. The first type (the simplest) is a rectangular box with a height equal to the height of the block. The area of ​​the box should contain the amount of mass from which several (4-9 pieces) aerated concrete elements can be made. If a significant amount of production of gas blocks is planned, then it is better to make a mold from a steel strip 4-5 mm thick. The structure must be collapsible to facilitate the excavation of the concrete blank. A removable cover must be provided on top. It is advisable to provide for its fastening to the sides of the box with bolts (screws) or other clamps. A simplified version of the form can be made of wood. For the sides of the box, a board with a thickness of 30-40 mm should be used.

The second type of shape is a lattice system. In this design, the cavity of the box is divided by partitions into cells in which one gas block is formed. This form can also be made of steel strip or wood. For internal partitions, plywood with a thickness of 12-15 mm can be used.

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Making aerated concrete at home

Before starting work inner surface forms must be thoroughly lubricated with machine oil to prevent sticking of the mass. It is recommended to heat the mold to a temperature of about 40º C. In an evenly mixed concrete mortar aluminum powder is introduced, and it is poured into the mold.

It is necessary to pour to a height approximately equal to half the height of the side of the box, which takes into account the expansion of the mass during the passage of a chemical reaction with the formation of pores.

A violent reaction with evolution of gas proceeds within 6-8 minutes. At this time, there is an active increase in the level of mass in the form. At the end of the reaction, the expansion of the composition stops, and then a slight shrinkage of the solution occurs. After the cessation of the vertical movement of the level, with the help of a strong steel string, all irregularities (bumps, sagging) are cut off from the surface of the workpiece. A heat-insulating material is applied over the calmed blank of the block: asbestos, polystyrene, etc. From above, the form is closed with a lid.

Natural drying of aerated concrete blocks is carried out. The minimum drying time is 2 hours. After that, the monolith can be cut into blocks of the desired size. The recommended time before transport to the storage site is 24 hours. In the process of work, it is necessary to exclude the occurrence of drafts. Fan operation is not recommended. The cooling of the mass should be slow and uniform.

Today, materials are increasingly being used for construction, which can be made by hand, purchasing only the necessary ingredients. All of them are characterized by excellent operational features, durability; their cost is not too high. One of these materials is aerated concrete. The laying of the blocks is simple, and the material itself has many advantages, including good thermal insulation properties, which are important for building a house.

Aerated concrete blocks have good thermal insulation properties.

Aerated concrete is not a novelty on the market, it was first used for construction at the beginning of the last century. Its active use in the construction of buildings began about 10 years ago. Although the aerated concrete manufacturing technology itself was patented by Erikson, an architect from Sweden, back in 1924.

Previously, aerated concrete was produced only in the factory, as this required exactly following the technology and selecting the proportion for mixing. The production itself is simple, but the weight of one block, which is obtained after pouring, is not the smallest, so the work must be done by at least two people.

For the production of aerated concrete you will need:

• Portland cement;
• quartz sand;
• aluminum powder;
• water;
• lime.

The manufacturing process itself is based on the use of one of 2 methods:

• autoclave;
• non-autoclave.

The first method is used in the factory, as it requires special equipment. Blocks after pouring are sintered under specially created conditions. You won’t be able to create them yourself, so it’s more practical to use the 2nd method. Concrete is poured into molds and dries naturally. The aerated concrete block is then removed and, if necessary, cut into pieces. Although it is better to immediately use for filling forms that correspond to the required dimensions.

To make aerated concrete blocks with your own hands, you need to prepare the following ingredients:

1. For each cubic meter of finished aerated concrete (by output), approximately 250-300 liters of water are required. It must be clean drinking water. It is best to take it from the surface layers of any clean sources.
2. Approximately 260-320 kg of cement is required per cubic meter of finished aerated concrete. For self-manufacturing brands M500D0, M400D0 are used.
3. Quarry sand, river, cleaned. Its quantity per cubic meter of the finished mixture is 250-350 kg. It is best to take a small one, the particle size of which is up to 2 mm. In no case is it allowed to keep branches, debris, clay.
4. Special additives for aerated concrete. Quantity 1-3 kg per cubic meter of finished mixture.
5. Gasifier, i.e. aluminum powder. Enough 0.5-0.7 kg for each finished cubic meter of concrete. Powder is needed in order for the mixture to start the reaction necessary for gas formation. During mixing, gas begins to be released, bubbles and cells form inside the concrete, which give the composition the qualities it needs.
6. Lubricant for containers in the amount of 0.3-0.5 kg per cubic meter. Before you start pouring with emulsions, the molds are thoroughly lubricated. Do not use used oils, as they contain a large amount of soot.

Making aerated concrete with your own hands is not so difficult, but it is important to follow all stages of production exactly, to select the ingredients for the future mixture in the correct proportion.

Equipment list:

1. Forms for pouring future aerated concrete blocks, which may have different size. It is best to purchase ready-made containers.
2. Strings that are needed to remove excess mixture from the surface of the molds.
3. A concrete mixer that will be used to mix the mixture.

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Ingredient Requirements

Make a large volume on your own building material will not work, but for the construction small house they are enough. Single block weight standard size can be approximately 650 kg. Therefore, the presence of several people is necessary not only for laying walls, but also for pouring molds, pulling aerated concrete blocks from containers. If all conditions are met, aerated concrete blocks will turn out to be durable and of high quality, their cost will be less than when buying a ready-made material.

You can use special installations that knead aerated concrete in automatic mode. They can be rented, but the equipment doses the ingredients on its own, mixes concrete of exactly the quality that is needed. Rental costs will be justified.

The proportions of aerated concrete may be different, but it is best to adhere to the following formula (for aerated concrete D-600):

• Portland cement PC500 D0 - 65%;
• purified sand - 30%;
• dolomite - 5%;
• V / T - up to 0.48.

Lime flour, i.e. dolomite, can contain up to about 10% aerated concrete, but it is important to decide what color of blocks is needed. With more lime, the color of aerated concrete blocks will be lighter. A large amount of powder is also not required, it acts as a catalyst for the gas formation reaction.

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Aerated concrete manufacturing process

To make cellular concrete, several steps must be followed, which include:

• dosage of ingredients, mixing of the dry mix;
• adding water, mixing the solution;
• filling the resulting mass of molds for pouring;
• exposure of the mixture to gain strength, drying of aerated concrete blocks and their removal from molds.

It is necessary to carefully measure all the dry ingredients needed for the production of aerated concrete blocks. The main materials are cement, lime, sand. To start the process of gas formation, it is necessary to use aluminum powder. After reacting with water, it provokes the release of hydrogen, the mixture begins to foam. Proportions are very important, since the strength, porosity and other characteristics of the future aerated concrete depend on them.

At the second stage, the components are mixed. The mass should be homogeneous. The quality of the batch also determines how the aerated concrete will be after preparation. Only special equipment should be used for mixing. Concrete mixers will do, this process is not done manually.

When the future concrete is mixed, it is necessary to start pouring it into forms.

Special forms are used, it is best to purchase ready-made ones that fully comply with all requirements.

Filling is carried out only up to half of the forms, in no case should they be filled completely. This is due to the fact that in the process of gas formation, the mixture greatly increases in volume, completely filling all the forms. After the increase in volume is completed, using a metal rod, it is necessary to remove all excess mixture from above so that the upper part is even and smooth. This is done approximately 6 hours after the filling has been completed.