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- a popular modern building material that has attracted many consumers for its lightness, low price and good performance. From its main competitor - - with its characteristic gray “concrete” color, lack of lime, features and production technology.

Equipment for the production of foam concrete

Installation

The main thing required is a special installation. There are several varieties of them - each is used for a specific production method. So, there are the following settings:

• Classic type– This is a mixer (equipped with special inclined blades) and a foam generator. The shaft of such a mixer makes from 35 to 60 revolutions per minute. The advantage of such a system is stable foam and simplicity of design. The downside is the cost of installation for foam concrete (price: from 1.16 million rubles). After all, the installation usually consists of an entire automated line.
• Bar mixers With high speed shaft rotation (from 200 to 400 rpm) do not use foam generators - in them the mixture is whipped into foam immediately. This requires more foaming agent. Equipment such as installations for the production of foam concrete of this type are quite mobile and compact. They can cost from 80 to 320 thousand rubles.
• You may also need equipment for the production of foam concrete blocks such as foam block cutting machine(if casting is done in one general shape). Such equipment is unlikely to be suitable for producing foam concrete with your own hands, because its price can range from 500 thousand to 1.7 million rubles.

This video will tell you more about installations and other equipment for producing foam concrete:

Forms

The quality largely depends on the shapes finished products. Therefore, their walls must be smooth and even, and their outlines must be geometrically correct. Molds can be with or without a bottom. Most often they are made with removable partitions - this is convenient. Molds are made from several materials:

• Metal(usually 4 to 6 millimeters thick) - durable, reliable, neat, but expensive. The cost of such products starts from 16 thousand rubles per piece.
• Laminated plywood will cost much less. One form will cost from 2.5 to 3.5 thousand rubles. To prevent delamination, the ends must be well treated (for example, with epoxy). Usually, high-quality plywood products completely pay for themselves.
• Plastic- Not the best option, since these forms usually do not provide the required clarity of size and configuration (although they have the advantage of not requiring lubrication). Their cost is low - about 100 rubles apiece. Experienced people recommend using fiberglass rather than plastic.

Raw materials

• The main expense item will be the purchase of a good one. Brands no lower than M500 (at least M400).
• foreign production - 42.5R or 52.5R.
• The water is preferably soft (it is better to warm it up a little).
• The sand is clean, free of debris, certainly well dried, with a fineness modulus of about 0.02 and a moisture content not exceeding 5 percent.
• Next, you will need fiberglass (it is used for reinforcement, strengthening foam blocks). Estimated cost– for 600 grams 160 rubles.
• Foaming agent is a necessary component. It can be synthetic or natural. An example of the first is the foam concentrate PB-2000, an example of the second is the protein foaming agent “Ekopen”. A 200 liter barrel will cost from 20 to 23 thousand rubles.

You may also need a plasticizer additive, hardening accelerators, and a special lubricant for molds.

Manufacturing technologies

Classical

Here, a concentrated foaming agent (usually an organic type) is mixed with the required amount of water and whipped using a foam generator. The remaining water according to the recipe, cement, fiberglass and sand are mixed to obtain concrete mortar.

The following video will tell you about foam concrete production technologies and the features of choosing equipment for this:

Barotechnology

All materials for the production of foam concrete (including synthetic foam concentrate) measured according to the recipe are fed into a high-speed mixer, where they are mixed for three to five minutes under pressure. In this case, the pores of the foam concrete are larger than in the previous one (which can negatively affect the strength). classic version, fed into molds.

Dry mineralization method

In the case of this foam concrete production technology, foam (obtained in a foam generator) is mixed with dry components. That is, cement, sand, fiberglass, and the additives required by the recipe.

Creation of thermal insulation materials

This material has the lowest density (400-500 kg/cm³). It is produced in accordance with GOST 25485, and does not contain sand.

Barotechnology is mainly used. However, classic method good too.

Setting up a production line

1. First, let's get a suitable room where there is high-quality ventilation, heating, water supply. Ceilings must be at least four meters. The production area is divided into four parts: two warehouses (finished products and raw materials), a drying chamber and Production Line.
2. The latter occupies an area of ​​at least one hundred square meters.
   • Next, equipment is purchased - domestic or imported. For example, the domestic lines “Fomm-prof”, “SANNY”, “PSB”, “PN-1100” are very popular. Well-known manufacturers, as a rule, provide certificates for their products.
   • An automatic installation with a steam generator with a capacity of 30 to 70 cubic meters per day will cost, for example, about 280 thousand rubles. Its advantage is ease of maintenance. It is enough to undergo a short training once, and a person will be able to work.

You will also need a compressor (about 40 thousand rubles), a two-ton loader (200 thousand rubles) and molds (their cost is listed above).

So, the initial preparation costs will be about 2.5 million rubles. Let's add the cost of raw materials - it's about a thousand rubles per cubic meter (very roughly). You will also have to pay wages to workers and foreman, and utility bills. However, as experience has shown, approximately everything pays off in five months.

It is worth remembering that you will be able to sell your foam blocks only upon receipt of a sanitary and epidemiological certificate. And one more thing: production is seasonal. Do not forget to also develop a business plan first, and also carefully study technological scheme

production of foam concrete.

The next section will tell you how to create it yourself at home using an installation for the production of foam concrete and foam concrete blocks.

Home craftsmen can easily make this material for their own needs, obtaining foam concrete with a density of 200 to 1200 kg/cm³. As a rule, equal amounts of sand (preferably sifted) and cement are taken. A kilogram of cement (M500 or M400) will require the addition of three to four grams of foaming agent. To accelerate hardening, it is recommended to add calcium chloride (up to two percent of the amount of cement).

To obtain stable foam, synthetic foam concentrate is preferable. However, there is another option (only if you use a steam generator) - make it yourself from heated and well mixed:

• rosin (1 kg);
• caustic soda (150 g);
• wood glue (60 g).

In accordance with the installation you have, we use classical or pressure technology (in this case, using a pressure installation for the production of foam concrete). By the way, many craftsmen cope with the manufacture of a steam generator on their own.

This requires a pump, a reservoir, a housing with a metal mesh, connecting hoses and a compressor. The foam concentrate mixed with water (this happens in the tank) is sent to the housing, where, under the pressure of the air jet of the compressor, it hits the mesh, forming foam. Its quality is easy to check: if it does not fall out of an inverted bucket, then everything is fine.

The components are placed in the mixer (first sand with water and cement, then foam). Remember - sand is not needed in the production of thermal insulating concrete. In a conventional vertical mixer with blades, everything is mixed for 20 minutes. If you take a barrel equipped with movable blades, you can handle it in two to three minutes. All work is carried out at plus five degrees and above.

The mixer must be supplied with compressed air from a compressor - this allows the mixture to be sent over a distance of up to forty meters. It is poured into molds (usually with convenient folding sides), always keeping it for at least a day. Metal and plywood molds require lubrication.

The finished blocks are placed on pallets and lie there for another 16 hours. They are then sent to a warehouse. Of these, it will be possible only after two weeks (otherwise there will be a lot of shrinkage).

The process of producing foam concrete at home is presented in this video:

• • Barotechnology
• • Molding technology
  • Cutting technology
• Drying blocks
• Paperwork
• Tax regime
  • • • Similar business ideas:

Foam blocks are a lightweight building material obtained by hardening a solution consisting of sand, cement, water, foam and chemical additives. The popularity of foam blocks is due to a number of advantages of this building material:

• Reliability. It is practically eternal, resistant to negative impact environment construction material;
• Heat. Foam blocks have high performance thermal resistance;
• Ease. Foam blocks are 2.5 times lighter than bricks and their consumption when laying walls is several times less than the consumption of bricks due to the reduction in wall thickness;
• Soundproofing. A building built on foam blocks has a high ability to absorb sound;
• Quick installation. Laying foam blocks because of their big size and precise geometry passes quite easily and quickly.
• and many other benefits.

In this regard, the demand for foam blocks from construction organizations And individuals there is always.

The advantages of producing foam blocks are as follows:

1. Low costs to start a business. To organize a mini-production of foam blocks, about 300 thousand rubles are enough;
2. Simple technology for the production of foam blocks;
3. Stable demand for this building material;
4. Not required to organize production large areas and a large staff of workers;
5. High indicators of economic efficiency of production. The profitability of foam block production is about 50%.

The production stages of foam blocks are as follows:

At the same time, depending on the type of equipment used and production technology, the quality, cost, speed of production of foam blocks, etc. change. First things first.

Preparation of foam concrete mixture

Today, two technologies are used to prepare foam concrete mixtures: pressure technology and the use of a steam generator.

Barotechnology

Barotechnology is more cheap way production of foam concrete. This production method does not require the purchase of expensive equipment and therefore it is very common in many small industries. The essence of barotechnology is that the main components of foam concrete are fed into the mixer: cement, water, sand, foaming agent, hardening accelerators, air-entraining additives (sometimes). Next, air is supplied to the mixer and all components are actively mixed. Then the resulting solution is fed under pressure into injection molds, where the foam concrete mixture increases in volume and takes on its final shape.

Advantages of this technology:

• Low production cost per unit of production and, as a consequence, low (competitive) unit selling price. The production process using barotechnology is simple and does not require large capital investments. Small production can be opened almost at home.

Disadvantages of this technology:

• Low strength of foam blocks due to large quantity water used when stirring the foam concrete mixture;
• Large pore size in foam blocks, which also reduces their strength and ultimately affects bearing capacity building walls;
• Synthetic foaming agents and plasticizing additives used in the process of mixing the foam concrete mixture (to create the mobility of the mixture) negatively affect the environmental friendliness of the finished foam concrete blocks.

Production of foam concrete using a foam generator

The production of foam concrete using a foam generator allows you to mix the components of the foam concrete mixture in the correct dosage, which has a positive effect on the strength and quality of the finished products.

The essence of this technology is as follows: using dispensers, first dry components in the form of cement and sand are fed into the mixer, and then liquid components in the form of water with chemical additives. Then the mixture begins to stir. Next, the finished technical foam is fed into the mixer and mixed with cement-sand mortar. To create the required density of foam blocks by adjusting the operating time of the foam generator, required quantity foam. Then the foam concrete mixture is supplied under compressor pressure to the installation site or into molds.

Thanks to the precise regulation of the dosing and saturation process, the production of foam blocks reaches a completely different quality level.

Advantages of this technology:

• Higher quality of finished foam blocks. Thanks to the use of pre-prepared foam, the output is more durable foam blocks, without large air pores and with the correct structure;
• The foam blocks are environmentally friendly, since environmentally friendly protein foaming agents are used in the production process.

Disadvantages of this technology:

• High cost of equipment for organizing production;
• Higher unit cost of production and, accordingly, higher selling price of foam blocks.

Today, the molding of foam blocks is carried out using two technologies: casting and cutting technology.

Molding technology

Casting technology involves pouring concrete mixture into special metal cassette molds. The most common cassette forms have a height of 600mm.

Advantages of this technology:

• Low cost of equipment (cassette molds);
• Simplicity of the molding process.

Disadvantages of this technology:

• Discrepancies in the geometry of finished blocks in height, length and width. This happens because when molding foam blocks, low-quality molds are used, often made in garage conditions. High-quality forms are quite expensive;
• To produce blocks of different sizes, you also need different shapes, which increases the cost of purchasing or manufacturing different forms;
• When stripping, partial damage to the corners and surface of the foam block occurs. This happens due to the block sticking to the walls of the cassette, and when it is removed, it has not yet gained the required strength. The foam blocks in the molds need to be allowed to stand for some time (about 10 hours), and due to the rush in production this rule often violated.

Cutting technology

Cutting technology consists of two stages of block forming:

A. Casting foam concrete mixture in big shape and stripping;

B. Cutting a large block into foam blocks of a given size.

This technology uses special cutting installations with different cutting elements (strings, band saws and chain saws).

The advantages of this technology are obvious:

• Excellent geometry of finished blocks, in accordance with GOST;
• There are no chips or damage to the surface of the foam blocks;
• Possibility of producing blocks different sizes. This is achieved by reconfiguring the pitch of the saw strings.

Disadvantages of this technology:

• When using different cutting elements, the requirements for the timeliness of cutting must be met. It is important to cut when the block has already hardened, but has not gained excess strength, otherwise the string will move, which will negatively affect the evenness of the block.

Drying blocks

Depending on the technology for molding foam blocks, the technology for drying products also differs.

With the injection molding production method, drying of blocks can be carried out in two ways:

1. Keeping the products in molds for 10 hours to gain strength and further demoulding the foam blocks;
2. Heat treatment of products in a steaming chamber, which allows the blocks to gain the necessary strength in just a few hours.

With cutting technology, a large mass of block is naturally held for 4 - 12 hours and then cut. Block cutting time the right size depends on the type of cutting elements and hardening accelerators added to the foam concrete mixture.

What equipment to choose for the production of foam blocks

We list the main equipment used in the production of foam blocks:

1. Pressure installation for preparing foam concrete mixture:

The cost of such an installation is about 100 thousand rubles.

2. Forms used in injection molding technology for the production of foam blocks:

A collapsible cassette mold for the production of blocks measuring 600×300×200 mm will cost about 30 thousand rubles. Up to 30 blocks are poured into this form at the same time.

3. Foam generator for preparing technical foam:

The cost of a new foam generator is about 90 thousand rubles.

4. Foam block cutting complex:

The cutting complex is the most expensive equipment in the foam block production system using cutting technology. On average, the price of one set is about 500 thousand rubles.

Other equipment used in the production of foam blocks includes: mixing stations, compressors, vibrating screens, etc.

How much money do you need to start a business producing foam blocks:

1. Creation of a mini-production of foam blocks using injection molding technology using a pressure unit to create a foam concrete mixture. To start such a business, about 300 thousand rubles are enough (if premises are found);
2. Mini-production of foam blocks using cutting technology using a foam generator to create a foam concrete mixture. Start-up costs are about 700 thousand rubles;
3. Purchase of a line for the production of foam blocks, including a full range of expensive equipment: mixing stations, foam generators, cutting complexes, etc. The purpose of purchasing such a line is to create an enterprise for the production of large volumes of foam blocks. Start-up costs in this case will amount to several million rubles.

Brief business plan for the production of foam blocks

Let's calculate the economic efficiency of organizing a mini-production of foam blocks, with a production volume of 330 m3 of foam blocks per month (22 working days) or 15 m3 per shift.

Initial data:

1. Productivity per shift - 15 m3;
2. Number of working days (shifts) per month - 22;
3. Production area - 500 m2, rental cost - 50 thousand rubles per month.

How much money do you need to open a mini-production of foam blocks?

The total starting investment for opening a mini production of foam blocks will be 421 thousand rubles.

Material costs for the production of 1m3 of foam concrete

The total cost of materials for the production of 1 m3 of foam block is 1590.13 rubles.

Conclusion: The net profit based on the results of the monthly operation of the enterprise for the production of foam blocks will be 406.4 thousand rubles. The profitability of production at such indicators is 60%, and the payback period for the equipment is only 1 month. Such indicators are possible subject to 100% sales of all manufactured products, which is 330 m3 of foam blocks per month.

Organization of a business for the production of foam blocks

The procedure for preparing documents for opening and developing your own company for the production of foam blocks includes the following steps:

• Collection of information and analysis of the situation on the building materials market.
• Creating a business plan.
• Analysis of the financial situation (if your own savings are not enough, you need to look for alternative sources financing).
• Business registration.
• Search for premises for workshop and administration.
• Conclusion labor contracts with company personnel.
• Product certification.
• Purchase of equipment and tools.
• Signing contracts with suppliers, buyers, etc.

Solution to the above
questions is quite a labor-intensive task, so

Many aspiring entrepreneurs turn to law firms in order to receive a ready-made package of documents for a certain fee (the cost of services depends on the region of residence and other factors).

Paperwork

Preparing papers for the legal production of foam blocks begins with choosing a legal form for your business. LLC registration is carried out if the owner of the company plans to work with government agencies and large companies. Entrepreneurs who focus on working with individuals can register as individual entrepreneurs. In addition, you will need the following documents:

• permits from the fire inspection and Rospotrebnadzor;
• certificates;
• invoices for raw materials;
• agreements with counterparties;
• certificate of opening a bank account.

Preparation of documents for the operation of an enterprise that specializes in the production of foam blocks is almost completely limited to the listed issues. For this direction commercial activities no need to obtain permits or licenses. To register a business and subsequent preparation of reporting, banking and other documents, you need to indicate the activity code (according to All-Russian classifier). In this case, it is OKVED 26.61.

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• for men

When constructing houses in Lately They are increasingly using homemade ones made from aerated concrete and foam concrete.

Foam concrete is ordinary cement mortar, which is mixed with a small amount of additives - foaming agents.

Foam concrete is a porous building material made from concrete saturated with a huge number of small air bubbles.

Manufacturing allows you to save money and time on transportation costs.

Advantages of the material

• modern foam concrete blocks allow air to pass through;
• moisture does not condense on them;
• they are soundproof and thermal insulation properties. 30 centimeters thick retains as much heat as 85 cm of expanded clay concrete or one and a half meters of brick;
• their cost is significantly lower than wood or brick;
• foam blocks are not afraid of fire;
• they are very easy to process (they cut, saw and drill well), without any problems you can screw self-tapping screws and screws into them, as well as drive nails;
• the smooth surface of the foam blocks can be finished with any known finishing materials;
• foam concrete is an environmentally friendly building material;
• blocks made from it are lightweight, their sizes allow you to save on mortar and maintain construction works at a faster pace.

Manufacturing equipment

Foam concrete is produced by foaming and the concrete mass is filled with air bubbles. It does the material is light, sound and heat insulating.

Existing technologies make it possible to produce foam concrete High Quality and blocks from it at home. To do this you need to acquire some equipment. In the future, it can become a source of additional or main income. For example, you can organize family business for the production of foam blocks at home.

The most required device- This is a concrete mixer. Mixers of various sizes and types with drum capacities from 60 to 240 liters can be purchased in stores construction equipment. With their help, a concrete solution is obtained. To convert concrete into foam concrete, a foam generator is needed. The finished foam concrete mixer with dimensions 1090 x 695 x 1500 cm weighs 250 kg. It can be transported in a trailer passenger car. Many models are equipped with wheels for easy movement around the construction site.

To cast foam blocks at home from a ready-made foam concrete mixture, you will need special molds, which are also sold in stores. You can make them yourself from sheet iron. It is acceptable to use plywood forms. But in this case, their bottom and walls are laid out plastic film so that moisture from the solution is not absorbed into the wood and the strength of the blocks is not impaired.

In addition to equipment, you will need the following materials:

• cement grades M-400 or M-500;
• river sand;
• special foaming agent (you can use the Penostrom brand);
• hardener;
• for final drying of the blocks you will need suitable premises under the roof. The temperature in it should not be lower than +5 degrees, and preferably 30-40 Celsius.

Preparation of concrete

Foam concrete production technology is the production of lightweight cellular concrete with the help of an additive cement-sand mixture- foam. Foam is produced in a special foam generator unit for foam concrete.

The process at home includes the following steps:

• sand, cement and water are mixed in a concrete mixer drum for about 30 seconds;
• a foaming agent is introduced into the resulting concrete mixture to saturate the solution with air bubbles;
• a foam stabilizer is added to the foam concrete (200 g of stabilizer is enough for 400 g of foaming agent);
• the drum rotates for about 3 minutes;
• the finished foam concrete mixture is poured into molds to produce blocks or directly into formwork to produce a monolithic structure;
• after a day, the blocks are removed from the molds and placed on pallets for final drying;
• after 16-20 hours the blocks are ready for their intended use;
• the molds are cleaned of concrete residues, their walls are lubricated with machine oil, and the entire process of making foam blocks is repeated.

To prepare 0.5 cubic meters of such concrete you need:

• cement - 200 kg;
• sifted river dry sand - 200 kg;
• water - 100 liters;
• foaming agent - 1.5 liters.

The recipe can be changed due to the introduction of other components into the concrete composition.

In this article:

Foam concrete is one of the most popular building materials for construction country houses, cottages, various extensions, as well as insulation and redevelopment of existing premises. In essence, foam concrete is a hardened mixture of cement, water and foam concentrate, a lightweight, fairly durable and cost-effective material with excellent thermal insulation properties.

Foam concrete market analysis

As a building material, foam concrete gained great popularity after it came into force SNIP 2-3-79. Since, according to new standards, building with brick has become economically unprofitable, foam concrete has become an ideal replacement for masonry, both internal and external walls. And the demand for this building material is growing steadily.

Today, the foam concrete market is in a stage of active development. Business relationship have a high level of loyalty:

• about 60% of consumers are ready to change suppliers if they are offered higher quality material in a similar price range or the same quality, but at a lower price;
• 30% - will look for new suppliers if the deadlines specified in the supply contract are not met (which is not surprising, since the pace of construction and the delivery date of the project depend on this);
• 10% are committed to long-term cooperation with one manufacturer.

Target consumer group and demand analysis

When organizing the production of foam concrete, sales should be calculated for medium and small construction. At large construction sites, foam concrete is used more as a material for thermal insulation and the construction of internal partitions, and quite rarely - as a structural material for the construction of external walls.

To assess the possible demand for foam concrete in your region, you should study not only the construction market, but also the real estate market: how high is the pace of suburban development, how popular is the construction of private houses, the reconstruction of old dachas, the construction of new cottages. On average across the country, demand for foam concrete is increasing every year, since this material has a number of advantages over wood and brick and is cheaper than its main “competitor” - aerated concrete.

Objectives of this analysis

1. Decide which production will be more in demand in your region:

• monolithic foam concrete (formwork, floor screeds);
• foam concrete blocks.

2. Determine the volume of future production.

3. Select a foam concrete production technology:

• classical(a water-cement solution is prepared separately in the mixer, to which foam is added from a foam generator);

• pressure technology(foam is whipped in the mixer at high speeds, to which cement and sand are added);
• porous- used for pouring directly on site, into the floor, voids, roof. Used for cooking mobile installations(a solution is prepared separately from sand and cement, water is supplied by a pump, a porosizer produces foam, which mixes into the solution and ready mix foam concrete is poured through a hose into the prepared form for hardening).

It is also worth thinking about choosing a “tool” for competition - about the advantage of your products over the offers of other suppliers.

It could be:

• flexible pricing policy (more low price, system of discounts, deferred payment, goods on credit);
• guarantee of delivery of materials on time (with possible payment of a penalty);
• free shipping;
• possibility of producing non-standard size blocks to order;
• free loading and unloading, etc.

Let's look at the example of the most common option - the production of foam concrete according to the principle classical technology followed by molding into foam blocks.

Planned production volumes are 40 m 3 /day (with the possibility of increasing to 70 m 3). Most popular size foam concrete block The dimensions are 600*300 or 600*200 mm.

Brands, depending on the density of foam concrete, are divided into:

• up to 500 - thermal insulation;
• 600-800 - structural and thermal insulation;
• from 900 - structural.

To produce foam concrete, you can purchase equipment from both imported and domestic manufacturers - installations such as “SANNY”, “Fomm-prof”, “PSB”, “PN-1100”. Manufacturers issue certificates for such equipment, and you can also purchase special foaming agents and other filler additives from them. Do not forget that if you issue a quality certificate (products made from binding materials are not subject to mandatory certification, but many buyers, especially large construction companies ready to cooperate only if it is available), all relevant documents will be required for the purchase of the production unit and all consumables.

To sell finished products, it is necessary to issue a sanitary and epidemiological report (at a minimum, conduct radiological and laboratory tests), since each batch of manufactured products must have an appropriate technical passport.

Installation for the production of foam concrete and other necessary equipment

It is planned to purchase an installation with a capacity of 30-70 m 3 /day based on a steam generator. Automation of equipment makes it possible to produce foam concrete of a programmed density (from 350 to 1200 kg/m 3) without the participation of a qualified professional. To work on such an installation, the shift foreman only needs to undergo training and set up the device correctly. The cost of such equipment with a working volume of 500 liters, all the necessary settings and additional option automatic water supply - RUB 277,000.

The kit includes:

• mixer;
• connecting hoses;
• built-in foam generator powered by a protein foaming agent;
• loading neck;
• installation of dosed water supply.

Additionally you need to purchase:

• compressor (with a capacity of at least 0.5 m 3 /min and a pressure of 6 atm.) - 40,000 rubles;
• high-precision molds for casting foam blocks 500*300*200 - 40 pcs.* RUB 49,900 = RUB 1,996,000;
• loader (2 tons), can be used - 200,000 rubles.

Total capital investments will cost RUB 2,513,000.

Foam concrete production technology

1. Preparation of raw materials

For the production of foam concrete, a foaming agent, M500 cement, unground fine sand, and water at temperatures up to +25°C are used. Depending on the recipe and brand of the future foam concrete, special ready-made additives are used - hardening accelerator (for the production of foam concrete at temperatures above +30 or below +15), fiber, expanded clay, etc.

2. Making foam

The foam concentrate, previously diluted with water, is sucked into the foaming unit. Here it foams under the influence of compressed air, and with the help of compressor pressure, it exits through the foam-generating pipe into the mixer. The texture of the foam can be adjusted using special valves for exiting the pipe from the most closed (less than 0.1 mm) to large pores.

3. Production of foam concrete mixture

Sand is poured into the mixer, then cement, the mixture is thoroughly mixed (the quality of the future foam concrete depends on the uniform distribution of sand in the cement). Afterwards, the mixture is mixed with water and kneaded until a plastic homogeneous mass is obtained. Foam is added to the mixer through a hose from the foam generator, and actively mixed with the cement-sand substance for 2-3 minutes.

4. Forming foam blocks

Molds for casting foam blocks are lubricated immediately before pouring (with special molding oil or lubricant such as “Emusol Bio”). Then they are filled with foam concrete mixture and left for 12 hours.

5. Drying foam blocks

The mold is disassembled, the blocks are taken out onto pallets and dried until completely hardened in a room with a controlled humidity level. The hardening time depends on temperature regime in room. At a temperature of +22 in 2 days the foam block gains 65-70% of brand strength (permissible tempering strength is 70-80%). At a temperature of +50 - for 8 hours.

Selection of premises for a mini-factory

Square production workshop depends on the planned volumes.

You will need a room with good ventilation, water supply, heated, with ceilings, a height of at least 4 m and zoned into four parts:

• warehouse for storing raw materials (cement, sand, etc.) ~ 50-70 m2;
• room where the production line is located ~ 100-120 m2;
• room for drying foam blocks ~ 60-100 m2;
• warehouse for finished products (can be stored outside, but only in warm time year at a temperature not lower than +15) ~ 70-100 m 2.

Cost of manufacturing 1 m 3 of foam concrete density. 600 kg/m 3

Consumables required for the production of 1m 3:

• cement M500 - 310 kg * 3 rubles = 806 rubles,
• sand - 210 kg * 0.25 rubles = 53 rubles,
• protein foaming agent - 1.2 l * 39.58 rubles = 47.50 rubles,
• lubricant for molds - 0.5 l * 25 rubles = 12.5 rubles,
• hardening accelerator - 0.5 kg * 36 rubles = 18 rubles.

Total: 937 rub.

From 1 m 3 of foam concrete, 28 pieces of foam blocks measuring 600 * 300 * 200 are obtained.

Business plan and payback calculation

Calculation of profit per month:

Planned capacity - 40 m 3 /day

Selling cost of 1 m 3 of foam concrete is 2100 rubles.

Total: profit (subject to work 24 days a month) - RUB 2,016,000/month.

Fixed monthly expenses:

• purchase of materials for production of 40 m 3 /day - (937 * 40 m 3 * 24 working days) = 899,520 rubles;
• workers' salary (6 general workers, 2 foremen and 1 accountant) - 73,000 rubles;
• rental of premises - 100,000 rubles;
• electricity - (160 kW/day * 2 rubles) 30 days = 9600 rubles;
• heating (it will take approximately 7 months a year, so we are not calculating the full amount, but 7/12 of the annual amount) - 21,000 rubles;
• other utility bills (garbage removal, water, etc.) - 2000 rubles;
• income tax (20%) - RUB 403,200.

Total: expenses – 1,508,320 rubles

Net monthly profit: RUB 507,680.

Calculation of return on capital investment:

RUB 2,513,000/RUB 507,680 = 5 months

But, despite such a rosy forecast, we should not forget that the production of foam concrete is seasonal, and in the cold season the products are not in demand, and costs increase (due to the cost of heating).

Therefore, in order to draw up a real business plan, you should not only replace the calculated data based on prices for materials, rent, tariffs for public utilities and salaries in your region, and calculate profits depending on your agreements on product sales.

Foam concrete is a popular building material, which has good thermal and soundproofing characteristics. Independent production foam concrete allows to reduce several times material costs. There are several construction technologies, according to which foam concrete is produced. We invite you to familiarize yourself with their features and methods of implementation.

Scope of use, types and advantages of home foam concrete

The popularity of foam concrete in the construction industry is explained by the following advantages:

1. Economic feasibility.

The production process does not require special material investments; the material is made from available materials, and the possibility of home production significantly reduces its cost.

2. Vapor permeability of foam concrete.

Due to the fact that the material allows air to pass through, a favorable and healthy atmosphere is created in the room, mold and mildew do not form.

3. Environmental safety.

Foam concrete - environmentally friendly pure material, since when production process no toxic substances are added to it. The main components are sand, water and cement. Some manufacturers improve the performance characteristics of the material by adding plasticizers and hardeners.

4. The material is light in weight.

This advantage greatly simplifies the process of transporting and laying foam concrete. In addition, such a house does not require a massive foundation, and construction work is carried out even in earthquake-prone areas.

5. Speed ​​of installation.

Using foam concrete as a building material for constructing walls allows you to build a house in 2-3 months.

6. High heat and sound insulation properties.

Making walls from foam concrete reduces the cost total cost buildings, as the costs of purchasing heat and sound insulating materials are reduced.

7. High level fire safety.

Foam concrete does not burn and does not support combustion; in addition, it prevents the spread of flame.

8. Versatility of further finishing.

Foam concrete walls are puttied, plastered, covered with wood, clapboard or siding. There are no restrictions in this regard.

Among the disadvantages of the material, we note high porosity, which, on the one hand, improves thermal insulation performance, and on the other, reduces strength. Therefore, transportation of foam concrete is carried out with extreme caution. Walls made of foam blocks in mandatory reinforced to avoid the appearance of cracks on their surface after shrinkage. In addition, foam block walls need finishing. Lack of external finishing leads to absorption carbon dioxide material and reducing its strength. High quality exterior finishing quickly solves this shortcoming. The best option- use of brick as a finishing layer.

The scope of use of foam blocks is not limited to the construction industry. The material is used to build walls, load-bearing structures V country houses, residential and office buildings. In addition, foam blocks are widely used in the process of insulating already erected walls, improving sound insulation, during the construction interior partitions. By using of this material reconstruct and repair old buildings, increase their number of storeys and improve sound insulation of floors.

Foam blocks vary in density and number of pores in the material. The letter D is used to denote this indicator. The production recipe of the material directly determines its quality and brand, and these indicators are the main ones in the field of using foam blocks. In relation to the place of application, the material is divided into:

• foam blocks from which they are built internal partitions D100-300;
• thermal insulation material D400-500;
• structural and thermal insulation D600-900;
• structural foam blocks D1000-1600.

Foam blocks itself high density They have the lowest thermal insulation properties and are used for reinforcing floors and structural work. Their cost is much higher than that of foam blocks of the D100-300 brand.

Please note that air humidity during the installation process should not exceed 60%. Otherwise, on inner surface material is applied vapor barrier film. To lay the material, both a regular cement-based mortar and a special glue are used. Usage adhesive composition has great advantages, since in this case, cold bridges do not form inside the walls. In addition, the amount of adhesive for fixing foam blocks is much less than cement.

DIY foam block press

The standard two-stage technology for manufacturing foam blocks involves the use of equipment in the form of:

• foam generator and compressor unit supplying air;
• mixer, at home, is replaced by a concrete mixer;
• forms for pouring the solution and hardening it;
• additional devices in the form of a pressure gauge and pumping equipment.

Before starting work, prepare drawings of equipment for the production of foam concrete. Next, purchase a module - the most expensive component. This part of the device converts the foaming agent into a foamy substance, supplying it to the solution.

The supply module serves as a place for pouring the solution that forms the foam. Any tank can handle this function, suitable size. Conversion module - processes the solution, making foam out of it. Dosing equipment - supplies foam in a certain density and quantity, determines the brand of the resulting material.

Among the main parts of the foam generator, we note the following elements:

• nozzles;
• connecting flange;
• suction pipe;
• body part;
• displacement chambers;
• diffuser

For self-made For this device, prepare two pipes, a pump, a hose, and a valve. Also, stock up welding machine and drawings according to which further work is carried out.

The factory pipe for the foam concentrate has a unique structure; one part of it has a narrow structure, gradually expanding. Thus, the speed of liquid passage through the pipe increases, increasing to its maximum at the outlet.

Next, start making the foam cartridge and chamber for the turbulent connection of the components. To do this, weld two pipes to one pipe. One of them is located in the end part, and the second is the foam supply, at the corner. Make sure that the nozzles are located at right angles to the tube.

Install two valves on each of the pipes:

• shut-off type - with its help the supply of the foam former is stopped;
• adjustable type - regulates the speed and amount of foam supplied.

Control valves are needed only for initial adjustment; they are not used later. Recommendation: the diameter of the side pipe should be twenty percent larger than the end pipe.

The next stage is working on the foam cartridge. The second pipe blank is equipped with a nozzle, which ensures the output of the finished composition. A funnel is installed at the outlet pipe, which reduces the rate of release of the foam concrete mixture. Install a filter inside the workpiece that converts the emulsion into foam. It is possible to purchase a ready-made filter or make it yourself from a regular dishwashing brush.

Please note that in this case, use a wire mesh, not a spiral one. Compact them along the entire length of the tube, to prevent the brush from falling out, additionally strengthen it with a washer.

Next, the mixing chamber is connected to the foam board. In this case, the installed pipes are located at opposite ends. To improve the speed of transport of the composition through the pipe, install an element in the form of a nozzle or jet washer between them. Please note that the second option, although cheaper, is worse, as it reduces the efficiency of the device by 30%.

Connect the compressor unit with the end pipe and the connection chamber. Please note that the compressor power must be at least 5 atm, in addition, it must have a receiver, pressure gauge and pressure relief valve.

Place the container on the floor, connect a hose to it to supply foam to the mixer. Connect the resulting installation with a pump, which will simplify the supply of foam. This device It is not inferior in power to a purchased installation, but its cost is 3-4 times lower.

The next stage is the construction of forms for foam blocks. Suitable for these purposes various materials such as wood, plywood, steel, polymers. The main requirement is to create a strong and flat surface, not prone to deformation. To make a mold, follow these steps:

• calculate the size;
• create a drawing.

Standard foam blocks in length, width, height in proportional terms are 4-2-1. Adhering to this ratio, the resulting material is suitable for the construction of walls and convenient dressing, without cutting the blocks. That is, with a mold depth of 15 cm, the width and height will be 30 and 60 cm.

In the individual production of foam blocks, thirty molds for a foam block are enough. Mount the partitions so that their largest part is located on top. Thus, foam blocks dry faster and gain strength evenly. It is possible to produce multi-level forms.

First, build the bottom of the mold, firmly fix the walls on it and install removable partitions inside. We recommend choosing a collapsible form, so the size of the foam block can be changed if necessary. When making a form from plywood, connect the parts together with nails and choose laminated versions. Homemade molds allow you to make foam blocks required size and shapes. Please note that before pouring foam concrete into molds wooden crafts pre-covered with film, otherwise the wood will absorb moisture from the solution and deform the characteristics of the resulting product.

Step-by-step instructions for making foam concrete

To make foam blocks you will need special equipment and mixtures. The composition of the solution for foam concrete includes the following ingredients:

• 310 kg of high quality cement;
• half a ton of fine sand;
• 210 liters of water;
• 1-2% foaming agent in relation to the mass of cement;
• modifying additives.

To make a foaming agent at home, mix the components in the following form:

• 150 grams of caustic soda;
• 1 kilogram of rosin;
• 60 grams of wood glue.

The foaming agent does not have to be made at home; ready-made formulations are an option. The instructions for the foaming agent for foam blocks indicate the proportion of addition to obtain a material of a particular brand.

To make your own foam concentrate, follow the instructions:

1. Prepare adhesive solution. Fill the glue with water in a ratio of one to ten, leave for a day. Next, heat the reservoir with the composition to a temperature of sixty degrees, stirring constantly, the mass should become homogeneous.

2. Rosin soap is prepared in this way: bring the soda to a boil, add rosin, boil the composition for 120 minutes until smooth. Rosin is pre-crushed.

When the soap cools to sixty degrees, combine the ingredients together in a ratio of one to six.

Pour the composition into a foam generator to obtain high-density foam. Optimal value foaming is eighty grams per cubic meter. With a lower value, quality deteriorates finished material and its thermal insulation characteristics.

The quality of the foam is determined in this way: fill the bucket with the composition and turn it over. If the foam is held tightly and does not flow out, then the proportions are correct.

The manufacturing scheme for foam blocks looks like this:

• supply of sand with cement;
• adding water;
• entry of the composition into the porosizer;
• feeding foam concrete into molds.

Please note that quite often the first 3-5 foam blocks do not work out required quality. This is due to the following reasons:

• the difficulty of adding components in the required dosage;
• decrease, increase in water level;
• a large amount of foam former;
• incorrect kneading time;
• determining the time to gain strength;
• selection of material drying mode.

By experimenting, all these indicators lead to the norm. Further formulations for the production of the material are constantly used. Defective foam blocks are used to fill the floor.

Foam blocks of grade D900 and higher are easier to produce, since they contain a small number of pores, however, they have lower thermal insulation properties.

DIY foam concrete video: