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

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, people have perked up almost all building materials with their own hands. At different times, the complexity of the work either increases or decreases, but in the 21st century this process has taken on new forms, because do-it-yourself production of gas silicate blocks began.

Main aspects of activity

Before you start making gas silicate blocks, you need to know many features of production.

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

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

In industry, an autoclaving element is used, but with manual work this is impossible, therefore, the activity is slightly redesigned.

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

There are many ways to cut aerated concrete, but it is better to immediately pour the desired shape, because when doing homework, unnecessary body movements will take too much time.

Saws and milling cutters for wood are commonly used because they make the perfect cut in no time, but you can use a jigsaw to shape.

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 just one crate can be made, depending on the required final strength, as well as the thickness of the product.

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The main variant of the work activity

It will use the standard sand cement mix, but the volume of the solution will be given as a trial in order to know exactly what will turn out in the end. The following tools and materials will be required:

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

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

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

And while 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 non-uniform places left. Mixing with a drill usually takes no more than 2-3 minutes, but in small volumes, 1 minute is enough.

Water is poured into the dry mixture, and you need to leave 200 ml in the jar. The plasticizer is poured into the water in the jar and sodium chloride is poured out. The resulting consistency is mixed, but without fanaticism, as was the case with the shavings. Here it is enough to chat for 20-25 seconds, and then move it aside.

The sand-cement mixture, already filled with water, is mixed for several minutes until smooth. It will take a little longer than for a dry premix, 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 this step should be monitored especially carefully.

Now you can add diluted water to the mixture as well as the 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 thinned mass.

As a test form, you can use any containers lubricated with machine oil or working off (as an option - plastic wrap). The solution is poured to 50% of the total volume of the container, because the remaining volume 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 of interframe spaces. Gas blocks do not give a large load on the foundation, since they have a cellular structure and low weight. It is an economical building material with high thermal insulation properties.

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

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

2. By designation, gas blocks can be heat-insulating, structural or structural-heat insulating. They have certain markings, for example, aerated concrete d500 belongs to the class of structural and thermal insulation blocks.

3. By form factor, they are divided into U-shaped, straight and groove-ridge.

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

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

The building mixture is transformed into artificially synthesized stone only under certain conditions. To obtain it, use the technology of autoclave hardening. 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 get autoclaved aerated concrete.

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

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

DIY aerated concrete

The production process consists of several stages:

• selection and mixing of components;
• filling forms with a solution;
• holding the composition for curing;
• extraction from forms.

The universal composition for producing aerated concrete contains cement, sand, lime, and aluminum powder. 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 building material with a lower density, you can make aerated concrete based on TPP resins.

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

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

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

• Portland cement - 90 kg;
• Water - 300 l;
• Gas generator - 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.

DIY instructions are not autoclaved aerated concrete

To obtain a gas block at home, you do not need complex equipment and tools. The main thing is to clearly follow the points below. step by step guide and use the components in a specific 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-sieved sand.

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

4. Add other components to the solution. The 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. It is best to use a concrete mixer to distribute the air bubbles evenly.

5. The resulting solution is poured into special forms, which are made of metal sheets or wooden boards... To make it easier to get the frozen aerated concrete, it is better to use collapsible structures. In addition, it is recommended to lubricate the mold with machine oil diluted with water.

6. You need to fill the mixture in half, since it almost doubles in the course of a chemical reaction. This process takes about six hours, after which the blocks can be straightened 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 accelerate the solidification process of the composition, it is recommended to add soluble sodium compounds (soda) at the stage of solution preparation. The material gains its grade strength after 28 days of aging. Ready non-autoclave gas block, prepared by hand, is suitable for low-rise construction, for example, for the construction of a one-story house or garage.

Private houses are often built from aerated concrete, because this material, at a low cost, has excellent operational properties. Aerated concrete has been used in construction for a very long time. It has established itself only on the positive side, if low structures (up to four floors) are being erected.

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

The main stages of manufacturing:

• Preparation of forms. Most often, a rectangular design is used, consisting of four sides and two. All structural parts are connected with bolts, which are treated with any machine oil.
• Preparation of the mixture. The initial components of the mixture are cement, lime, sand and warm water. A blowing agent is also used. Sand must be screened out before maximum size in 2.1 unit. The clay content in the sand should not exceed seven percent. As for the cement, the M-400 or M-500 brands are taken. The ratio of the components is approximately as follows: 51-71% cement, 0.04-0.09% aluminum paste, 1-5% lime, 20-40% sand and 0.25-0.8% water.
• Filling the form. The mixture is poured into prepared forms, which must first be warmed up 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 flow of the process of pore formation and hardening of the product.
• Drying of blocks... It is carried out already two hours after pouring. The block is taken out of the mold and sent to a warm warehouse or to special chambers to complete the production process.

Aerated concrete wall blocks are products made from aerated concrete. What are its features and what is this building material in general.

Aerated concrete was invented long ago, but with the development of new modern production technologies, improved aerated concrete blocks of various designs and types began to be produced. When constructing 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 we are talking about fixed lines... They are suitable for the production of non-autoclaved aerated concrete.

Autoclaved aerated concrete gains strength when high pressure and the temperature in a special chamber called an autoclave. The non-autoclave version hardens in its natural environment using warm exposure.

The maximum productivity of the stationary line is 60 cubic meters. it automated productionthat requires minimal human presence.

Special equipment helps storage and transportation, and automatic dispensers measure out the required number of components themselves. The blocks are of high quality, but this is an expensive equipment that 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:

Forms for production

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

• Collapsible. The mass poured into such forms can be combined by simply removing the sides. They are collected on empty pallets. Most of the work with forms is done by hand, but this increases labor costs.
• Caps. 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 forms speed up the production process, but also require minimal manual labor.

After removing finished blocks from any type of container, it must be cleaned and thoroughly 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 plant "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 private house without unnecessary financial costs for finding a manufacturer and delivering finished products.

The installation also includes:

• Electrical engine;
• Dispensing hose;
• A disc with a full description of all stages of work. Therefore, it is not necessary to have special qualifications to start manufacturing. It is enough to read the information on the disc.

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

Cost of equipment

The final price depends on the power of the equipment and its specific configuration. The mixer is all expensive, the main part of the price of which consists of dispensers and molds. 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 more reduce the cost of building your own house or summer 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 production technology of non-autoclaved porous concrete. The formulation contains available and widely available materials, and the conditions for maturation of the formulation 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 made of porous concrete. The material itself is a type 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 mix has the following composition: cement, sand, aluminum powder, water, as well as various additives.

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

The non-autoclave manufacturing method is realized in natural conditions, which allows it to be used independently. 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 takes place in a closed form inside a viscous mass, then the gases form pores in the bulk of this material. Even after the gases leave the mixture, the pores remain in 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 in combination 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 producing non-autoclaved aerated concrete includes several mandatory stages 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 molds with sufficient strength. The inner 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 stationary 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 a number of necessary works are performed.

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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;
• a hammer;
• shovel;
• mixer;
• ruler;
• hair dryer for construction;
• master OK;
• putty knife;
• steel string;
• chisel;
• chisel;
• libra;
• measuring bucket.

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Mix preparation

A standard aerated concrete mix contains cement, sand, water and lime. Aluminum powder is used as a pore-forming agent. Slaked lime plays the role of 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 M400 or M500 Portland cement.The filler is taken in the form of quartz sand. It should be carefully sieved to remove coarse fractions. Clay in the sand can only be in the form of small traces and make up 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 cement content and pore-forming composition, it is possible to control the pore volume in the concrete, that is, to change the density of the material.

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Form making

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 block height. The area of \u200b\u200bthe box should contain the volume of the mass, from which several (4-9 pieces) of aerated concrete elements can be made. If a significant volume of production of gas blocks is planned, then it is better to make the mold from a steel strip 4-5 mm thick. The structure should be demountable 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 using bolts (screws) or other clamps. A simplified 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 form 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 shape can also be made from 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, the inner surface of the mold must be thoroughly lubricated with machine oil to prevent adhesion of the mass. It is recommended to warm the mold to a temperature of about 40 ° C. In uniformly mixed concrete mortar aluminum powder is introduced and it is poured into the mold.

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

A violent reaction with gas evolution 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 stopping the vertical movement of the level, using a strong steel string, all irregularities (bumps, nodules) are cut from the surface of the workpiece. A heat-insulating material is applied over the calming block blank: asbestos, polystyrene, etc. From above, the mold is closed with a lid.

Natural drying of aerated concrete blocks is carried out. The minimum drying time is 2 hours. The monolith can then be cut into blocks of the desired size. Recommended time prior to transport to 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 that can be made by hand by purchasing only the necessary ingredients are increasingly being used for construction. All of them are characterized by excellent performance characteristics, durability; their cost comes out as a result not too high. One of these materials is aerated concrete. Laying the blocks is simple, and the material itself has numerous 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 Erickson, an architect from Sweden, back in 1924.

Previously, aerated concrete was produced only in the factory, since this required exactly observing the technology and the selection of 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 at least by 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 at the factory, since it requires special equipment. After casting, the blocks are sintered under specially created conditions. You won't be able to create them on your own, so it's more practical to use the 2nd method. The concrete is poured into molds and dries naturally. The aerated concrete block is then removed and cut into pieces if necessary. Although it is better to immediately use it for filling the 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 (at the exit), approximately 250-300 liters of water are required. This should be clean drinking water. It is best taken from the surface layers of any clean source.
2. About 260-320 kg of cement is required per cubic meter of finished aerated concrete. For self-made used brands M500D0, M400D0.
3. Quarry sand, river, cleaned. Its quantity per cubic meter of 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 the content of branches, debris, clay allowed.
4. Special additives for aerated concrete. The amount is 1-3 kg for each cubic meter of the finished mixture.
5. A blowing agent, i.e., aluminum powder. Enough 0.5-0.7 kg for each finished cubic meter of concrete. Powder is needed so that the reaction necessary for gas formation begins in the mixture. During mixing, gas begins to evolve, 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 starting filling with emulsions, the forms are carefully lubricated. Waste oils must not be used 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, which are necessary to remove excess mixture from the surface of the forms.
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 quite enough. Weight of one block standard size can be about 650 kg. Therefore, the presence of several people is necessary, not only for laying the walls, but also for pouring forms, pulling out aerated concrete blocks from containers. When all the conditions are met, aerated concrete blocks will turn out to be durable and of high quality, their cost will be less than when buying ready-made material.

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

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

• portland cement PC500 D0 - 65%;
• refined sand - 30%;
• dolomite - 5%;
• W / T - up to 0.48.

Lime flour, i.e. dolomite, can contain up to about 10% of aerated concrete, but it is important to determine what color of blocks is needed. With a larger amount of 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 gassing reaction.

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Aerated concrete manufacturing process

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

• dosage of ingredients, mixing dry mixture;
• adding water, mixing the solution;
• filling the resulting mass of forms for filling;
• holding the mixture for curing, drying aerated concrete blocks and removing them from the molds.

It is necessary to carefully measure all dry ingredients required for the production of aerated concrete blocks. The main materials are cement, lime, sand. To start the gassing process, it is necessary to use aluminum powder. After reaction with water, it provokes the evolution of hydrogen, the mixture begins to foam. The 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 what aerated concrete will be after preparation. Use only special equipment 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 the molds.

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

Filling is carried out only up to half of the forms, in no case should they be completely filled. 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, with the help of 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 pouring was performed.