Building blocks are the usual material for the construction of structures for various purposes. They differ in size, constituent components, manufacturing method, but all are in demand wall construction material. Building blocks are manufactured in an industrial environment, in the household they also make concrete products and cinder blocks, which requires installation for the production of building blocks with their own hands. According to the material of manufacture, these products are divided into the following types:
- slag concrete;
- concrete;
- building blocks from sawdust;
- aerated concrete;
- fiber-reinforced concrete;
- polystyrene concrete.
Cinder blocks as a building material
Slag stone refers to standard concrete products, only instead of heavy gravel and crushed stone, aggregate in the form of waste slag is used. Such a replacement gives the material lightness compared to concrete and additional thermal insulation properties, since slag compares favorably with heavy and dense crushed stone in terms of thermal conductivity.
The production of cinder blocks provides for the exact dosage of the components in solution, namely:
- brand cement is not lower than 400 or 500, one part is taken (bucket);
- quarry sand, 3 parts (buckets) are kneaded;
- slag, burnt brick, expanded clay, this material is added in an amount of 5 parts (buckets);
- water.
To obtain cinder blocks of the same quality as in the factory, use a solution of medium viscous consistency. A liquid solution will reduce the strength of the blocks, and a thick one will create uncontrolled voids inside when solidified.
Concrete blocks
Building blocks of cement, sand and gravel are used for the construction of wall and other structures, if increased strength is required. The ratio of components for standard concrete is taken in a ratio of 1: 3: 6, other versions of the concrete mix are described in the builder’s guides and depend on the brand of cement used, the size of the aggregate and the type of sand.
Sawdust building blocks
For the construction of residential houses, cottages, cottages use light and warm wall material from sawdust, sand and water. Lime is an astringent component in the solution. The amount of material added to the solution changes the properties of the final product. An increase in the mass of sawdust leads to an increase in thermal insulation properties, but contributes to a decrease in strength. With an increase in the amount of sand in the solution, an increase in strength occurs, while the limit of frost resistance increases, which increases the operational properties of the material. Blocks are widely used in private housing construction as a casing for thermal insulation of structures.
The main advantages of the blocks are the availability of materials and low price, long term of use without destruction, environmental cleanliness of the material, ease of preparation. A do-it-yourself installation for the production of building blocks is available in manufacturing and is popular among home craftsmen. Sawdust is characterized by increased drying time, so several through holes are made inside the product to improve air flow.
The sizes of sawdust blocks are not strictly regulated, their width is taken as a multiple of the wall thickness indicator. If we talk about standard sizes, then the blocks are made at twice the thickness of the brick (140 mm - 65x2 + 10 cm). In the manufacture of sawdust stones, dry components are first mixed, then water is added, and a mortar mixer is used for work.
Aerated concrete building blocks
Their preparation involves a complex process of saturation of the solution with gases, which is difficult to reproduce at home. Aerated concrete building blocks are lightweight, high soundproof, heat-insulating properties.
Fiber-concrete products for masonry
Fiber-concrete is inherently an environmentally friendly wall material containing sand, foam and cement. High-tech machines for building blocks spray foam in the mass of the solution, it forms uniform closed particles of space. To increase the strength of the blocks, manufacturers use fiber reinforced polyamide throughout the mass. Such wall material is very durable, does not rot, light and strong.
Blocks of their fibropenobeton produce various sizes. For load-bearing walls, a block size of 20x30x60 cm is used, which weighs 22 kg. To build a wall of brick of the same size, 18 stones are required, they will weigh 72 kg. Blocks of smaller thickness (10 cm) are used in the construction of walls inside the building, partitions, they insulate floors, walls. The thermal conductivity of fiber-reinforced concrete is less than that of brick, 2.7 times and 2 times less than that of slag concrete and shell rock.
The large size of the blocks reduces the use of cement-sand mortar for masonry by 20 times compared with the construction of a wall of small stones. Fiber-concrete does not burn, when exposed to high temperatures does not change shape and does not emit harmful impurities when heated.
Polystyrene blocks
The material belongs to the next variety of lightweight wall concrete blocks. It differs from standard concrete in the best operational qualities and reduction in production costs. The innovative wall material surpasses all known lightweight concrete in weight, even foam concrete is one and a half times heavier than it. Thanks to this indicator, houses are built without the usual massive foundation, the cost of transporting material is reduced.
The production of polystyrene foam blocks includes the careful combination of cement, sand, polystyrene particles and special additives to hold air in the total mass. All other physical characteristics of the material put it a notch higher than conventional materials. Low water absorption and vapor permeability make polystyrene foam concrete resistant to repeated freezing and thawing, which affects the durability of the structures under construction. After the construction of walls from standard materials, a slight shrinkage occurs during the year. In the case of polystyrene blocks, such a time is not expected.
DIY building block production plant
For the manufacture of building structures use a special device that works on the principle of a vibroprocessor.
Such a vibrating machine or vibrating table is constructed independently. A self-made installation for the production of building blocks significantly reduces the cost of the blocks, respectively, and the walls of the house.
Solution preparation
The solution is prepared from sand, cement, water and aggregate, which are used as various materials, as described above. To check the consistency of the solution for fluidity, a small amount is thrown to the ground. A high-quality mixture does not spread by watery streams; when compressed in a fist, it sticks together into a lump.
The production of slag blocks involves thorough cleaning of the slag from extraneous debris; chips, unburned parts of coal are not allowed to enter the solution. Sometimes gypsum is added to the solution. In this case, three parts of slag and one part of gypsum are mixed, while water is introduced. This solution is quickly used as gypsum hardens in minutes. Preliminarily slag before kneading is soaked with water. To improve the quality of products at the outlet, modern plasticizer additives are added to the solution. Their action increases frost resistance, water resistance and mechanical strength of the blocks.
Depending on the purpose, two types of concrete blocks are made - solid and hollow. The former are used for the construction of durable structures, load-bearing walls, foundations. The second type of blocks is used as the material of the partitions; it well insulates the building envelope from the cold and extraneous sounds.
Production of concrete blocks without vibrating table
Of the two technologies, the use of a wooden mold, which is intended for the natural spreading of the solution without vibration, is in non-decreasing demand. The placement of the solution in the prepared form is carried out in several stages. First, the container is poured with a solution by a third, after which the walls of the mold are carefully tapped with a hammer around the perimeter for high-quality shrinkage of the concrete solution. In the next two stages, the solution is poured according to the original technology until the form is filled. The manufacture of building blocks with voids involves a method when two plastic bottles of water are inserted into an uncured solution, which are removed after setting.
Forms are left for 2-5 days to dry. Then, the blocks are carefully removed from the collapsible structure and laid out on pallets until completely dry. A slag stone machine with this production method is not required to be purchased.
Of tools and devices you will need: a sieve for sifting sand, a mold for mortar, a mixing trough or a concrete mixer, a hammer for tapping, a bucket, a shovel, a trowel, drying trays.
Method of manufacturing blocks using a vibrating machine
To do this, a vibrating machine for cinder blocks is purchased or manufactured independently. A special form of metal is installed on the plane of the machine, and concrete mixture with aggregate from slag is poured into it by one third. After that, the vibrating table is connected to the action for up to 20 seconds, which allows you to remove all unnecessary air bubbles from the solution, and the cement will get a good shrink. The solution is poured into the mold three times. The blocks are removed from the mold in the same way as in the manufacturing method without vibration.
The cinder block does not tolerate overdrying in hot weather in the open sun, so it is sprayed with water on hot days and covered with oilcloth or cellophane so that moisture does not evaporate so actively. Formed, fully dried concrete blocks gain 100% strength on the 28th day, and after that they are ready for use in construction.
Features of the manufacture of cinder blocks
Molds are made independently, using metal or wood for this, boards take at least 190-200 mm in width. They are connected into a prefabricated structure, the side parts of which are disconnected to extract the finished block. The total design combines no more than 6 cells for laying concrete. The finished structure is installed on a dense waterproof material, for example, an oilcloth forming the bottom of the mold.
If wood is selected as the material for the mold, then it is pre-treated with impregnations or primers to increase moisture resistance. Molds are made of dry wood. These conditions are met, otherwise in the process the tree will lead from the water, and the geometric size of the block will change. The standard sizes of stones are 400x200x200 mm, but each manufacturer-private trader makes blocks for his construction.
For metal matrices, sheets no more than 3-4 mm thick are taken. When welding the structure, all welds are made outside so as not to round the corners of the block. The voids inside the cinder block are made using pieces of metal pipes of suitable diameter, for example 80 mm. The distance between the pipes and the distance from the walls are controlled, the composition is welded with strips for rigidity and fixation.
If equipment is being made for the production of building blocks, then when the vibrator is attached to the table after tightening the nuts, they are still slightly welded. The motor must be closed with a protective casing of any material from spray of solution, water, dust.
Production technology of sawdust concrete blocks
Available materials are not pre-processed, and you can buy them at any hardware store, so the production of blocks of sand, lime and sawdust is started immediately after purchase. To mix the mortar, a concrete mixer or mortar mixer is used, since it is difficult to manually mix wood waste.
Dry sawdust, passed through a large sieve, is mixed with sand and cement. Lime or prepared clay dough is added to the solution. The resulting mixture is mixed well and only after that water is added, gradually pouring it in small portions. To determine the readiness of the solution, it is squeezed in the hand, after which fingerprints should remain on the lump, which indicates the correct proportions.
Before filling the forms with a solution, they are lined with a thin layer of sawdust. The internal holes in the blocks are made using wooden plugs about 70-80 mm in size, which are installed in the matrix before pouring the solution. The material of the building blocks is tightly packed into the mold using a special tamper. The container is filled to the top and left to dry for three days. After this period, the solution gains about 40% of the required strength.
The molds are disassembled, and the blocks are dried for another four days, after which the strength becomes 70% of the set limit. Finished products are transferred to pallets and covered from direct sunlight. The drying of the blocks is faster, if during the storage process to leave gaps between the products. It is advisable to place pallets in a draft or use a fan for forced blowing.
Sawdust concrete blocks gain 100% strength after drying for 3 months, but they can be used after a month of ventilation. At this time, their strength is 90%.
Machine tools and equipment
To make the number of blocks necessary for construction, a ready-made vibroforming machine is purchased. The TL-105 brand is distinguished by good performance. And although its power is only 0.55 kW, it produces about 150 concrete blocks with different aggregates in an hour of operation. Its approximate cost in the market is approximately 42,800 rubles. Modern manufacturers of machine tools produce many varieties of machines for the production of blocks with additional functions. The prices for machines are different, and the cost of building blocks directly depends on this.
For small private construction, 1IKS vibrating machine is suitable, it costs about 17,000 rubles, power - only 0.15 kW, it produces such equipment 30 blocks per hour. When buying a machine, take into account the level of production of blocks for the needs of construction.
In conclusion, it should be noted that the manufacture of building blocks with one's own hands will save a lot of money on the production of products. Cost does not take into account the wages paid to the employee. Overhead and manufacturing costs, taxes and other deductions are not added to the cost of the block, therefore, to make building material cheaper at home.