Foam block production technology, dosage. General description of the material

At the beginning, I would like to say that contrary to the prevailing opinion that foam concrete is concrete with air inside, let’s say it is air balloons, the shell of which is ordinary concrete.

Foam concrete production technology can be four types: using a foam generator, at excess pressure, turbulent resonant cavitation dispersion, using a foam generator and a dispersant. Let's look at each of them in detail, because each has its own pros and cons.

The composition of any foam concrete necessarily includes water, cement and a foaming agent. As a filler, you can use quartz sand (without clay), ash waste, microspheres, water treatment waste and even waste slag from metallurgical production. As a rule, all foam concrete is non-autoclaved, unlike.

1 Preparation of foam concrete using a foam generator(the most ancient")

The method is as follows: in a low-speed mixer, usually with horizontal arrangement rotor, a cement-sand mortar is prepared. Separately, a foam solution is prepared in a foam generator. The foam is then mixed with cement mortar.

The pressure at which air entrainment (foaming) occurs is equal to atmospheric pressure.

Plus:

the ability to use all types of foaming agents: from protein to synthetic.

Minuses:

the presence of unstable bubbles in the foam and its partial destruction (sediment) even before the setting period;
impossibility of obtaining low-density foam concrete (grades below 500);
impossibility of high-quality dispersed reinforcement for producing fiber foam concrete;
Installations of this type are very cumbersome and do not make it possible to carry out monolithic casting on site.

Result: As a rule, blocks obtained by this method have a non-uniform structure and are susceptible to cracking due to the internal stress of the material itself. In one batch, the specific mass density can vary up to 100 units.

2 Preparation of foam concrete under excess pressure

A method developed by MGSU (Moscow) in 1979. Its essence is that all components are loaded into a pressure mixer with a vertical rotor at once and pore formation occurs at excess pressure.

Pros:

this mixer can be used as a foam concrete pump, since the foam concrete is removed from the mixer through a hose;
These installations come in different sizes. Small ones (up to 200 liters) can be transported to the construction site.

Minuses:

inability to carry out dispersed reinforcement of foam concrete with fiber;
high coefficient of variation in mixture density from batch to batch;
mandatory presence of a compressor;
only a synthetic foaming agent is used, and in large quantities;
due to high blood pressure In the mixer flask, rapid wear of the rotor seals occurs.

Result: Due to high pressure, foam concrete obtained by this method “chokes” when removed from the mixer. The blocks turn out to be unstable, crack while still in the warehouse and are extremely difficult to transport to the place of laying.

3 Preparation of foam concrete using turbulent resonance cavitation dispersion technology

Preparation is carried out in open mixers with a vertical rotor. Due to the high speeds and guides inside the mixer flask, the solution (mixture) is thrown onto the mixer stacks. It turns out to be a funnel (cavity). A zone of low pressure (up to 0.8 bar) forms at its bottom. The mixture constantly circulates vertically and, in order to compensate for the difference with atmospheric pressure, begins to “absorb” air. This process is called the “physical effect of turbulent cavitation.” Moreover, this process occurs evenly.
When installation parameters are agreed upon by special in a special way, at the cavity boundary the phenomenon of resonance occurs in a liquid medium. As a result, cement and sand particles are crushed and air bubbles are minimized.
The kneading lasts no more than 6 minutes (with a good foaming agent).
Settings:

pros:

sustainable foam concrete mixture. Its bubbles do not burst (finely dispersed closed porosity), which increases the thermal resistance of the material by 1.5 times compared to GOST requirements;
Due to the closed pores, this foam concrete is waterproof (floats in water). Its water saturation is no more than 11%;
coefficient of variation in density from batch to batch is no more than 4%;
you can use sands with a particle size module of 1 – 3, without pre-grinding;
possibility of using fiber with a fiber length of up to 70 mm;
all installations are mobile and can be used for pouring monolithic walls;
possibility of using “low” grades of cement (ShPTs 400);
low shrinkage of foam concrete when it dries;
the possibility of obtaining foam concrete of “low” grades, up to 100.

Minus:

the installation only works if there is a good synthetic foaming agent.

Result: Foam concrete produced using this technology can withstand transportation comfortably. It can be placed on glue, with a layer thickness of up to 3 mm. Due to the use of fiber, there are no “cobwebs” on it.

4 Producing foam concrete in a continuous manner using a foam generator and dispersant

Foam concrete using this technology was produced only in laboratory conditions. Unlike the first method, here there is high-speed in-line mixing of a small volume of a mixture of foam and cement-sand mortar. This technology requires the presence of a foam generator, a dispenser for the flow of mortar mixture and foam, and a gerotor pump.

Minus:

large coefficient of variation of densities (15 – 24%). Using this technology, it is impossible to obtain fiberized foam concrete, due to which it has a high probability of cracking.

Plus:

These plants can produce ultra-light foam blocks in large quantities.

After considering all the cooking technologies, let’s focus on the general advantages and disadvantages of this material . For comparison, you can look at “” described earlier.

Among the common advantages of foam concrete, It should be noted:

Organizing the production of foam concrete does not require large investments and huge workshops.
No production required high costs energy.
It is possible to fill floors, roofs and monolithic walls (with certain technologies).
The possibility of fibration thereby increases strength characteristics, on average by 25%, without increasing density.
Good workability of the material.
Due to the fact that the pores in foam concrete are closed, there is low moisture and vapor permeability. Foam concrete is not blown by the wind.
Due to the fact that cement is used as a binder, over the years, foam concrete only gains its strength characteristics, and does not lose them, like aerated concrete. For comparison;
Due to the fact that foam concrete is not aggressive to metal, large construction elements can be made from it - lintels, floor slabs, etc.

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, lightweight, quite durable and economically advantageous 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 the new standards, building with brick has become economically unprofitable, foam concrete has become perfect replacement for laying 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 more High Quality 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. On large construction sites foam concrete is more used as a material for thermal insulation and the construction of internal partitions, and quite rarely - as construction material 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 price 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 both imported and domestic manufacturer- 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, are ready to cooperate only if it is available), all relevant documents will be required for the purchase of a production plant and all consumables.

For sale 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 configure the device correctly. The cost of such equipment with a working volume of 500 liters, all the necessary settings and the additional option of automatic water supply is 277,000 rubles.

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 it is located Production Line~ 100-120 m2;
room for drying foam blocks ~ 60-100 m2;
warehouse for finished products (can be stored outside, but only in the warm season at a temperature not lower than +15) ~ 70-100 m2.

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 don’t expect full amount, and 7/12 annual) - 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- this is cellular concrete, which has a porous structure due to bubbles distributed throughout the volume, obtained as a result of hardening of a solution consisting of cement, sand, water and foaming agent.

In the 19th century, builders mixed ox blood into cement-lime mortar, and the blood protein reacted with the solution to form foam. Due to the difficulty of obtaining large quantity Foaming agent was not widely used at that time. Foam concrete was “rediscovered” in the thirties of the last century. At that time, the Soviet scientist, experimental builder Bryushkov, added to the cement mortar soap root. Over the years, during the production process, specialists began to try mixing cement with various chemical additives - foam and gas-forming substances, namely: aluminum powder, glue rosin solution.

Foam concrete production technology

general information

Its manufacturing technology is based on mixing pre-prepared foam with mortar mixture. As for the foam concentrate and water, when producing foam they are dosed by volume. After that ready solution mixed and thus a foaming agent for foam concrete is obtained. Next, the production of foam concrete occurs as follows: the foaming agent is supplied to the foam generator, in which foam is formed. After this, foam from the foam generator is transferred to the concrete mixer and this mixture is mixed for approximately three to five minutes. Then, the finished foam concrete is transported through a flexible hose to the place where it is laid in a mold or formwork.

Component consumption during production

To prepare 1 cubic meter of foam concrete, 500 kilograms of cement are required. To prepare foam concrete with a density of 300 kilograms per cubic meter 270 kilograms of cement are needed. Let's look at what materials are needed to prepare a foam concrete mixture. Firstly, cement. Secondly, placeholders. Large aggregates are: but gravel is not needed for production. Sometimes it is possible to add a lightweight aggregate such as expanded clay. In this case, the strength of porous concrete increases by approximately 100-200%. Fine aggregates are: natural or crushed sands. And it is considered most preferable for production river sand. This filler must be clean and free of various inclusions.

For installation, fine sand of approximately 0.2 millimeters is used. As for clay inclusions, they should not exceed more than 3 percent. Thirdly, water. The production of foam concrete requires the use of water without any testing. The water content of porous concrete consists of the calculated quantity. So, before adding foam, the water-cement ratio of the solution must be at least 0.38. If the water-cement ratio is too low, foam foam will be obtained with a higher bulk density. This can happen as a result of the fact that the concrete during the production process begins to take away from the foam the water required for chemical and physical interactions, and the foam will partially begin to collapse, and this will lead to a decrease in its volume in the foam concrete mixture. The most optimal ratio is in the range from 0.4 to 0.45. In this case, the water temperature should not exceed 25 degrees.

Experts advise using protein foam concentrate as a foaming agent for production. This substance must be stored in hermetically sealed wooden or plastic barrels. Such barrels must be hidden from direct contact sun rays. They should also be stored at a temperature no higher than +30 degrees. From the moment of preparation, foam concentrate can be stored for 15 to 30 days.

Preparation of foam concrete mixture + video on how to do it

When preparing the mixture, first of all, sand is poured in, then cement is added and everything is thoroughly mixed until the color of the mixture is uniform. It is quite important to distribute the cement well in the sand. Then water is added to the mixture in the amount specified in the selected production recipe. The mixture is mixed until a homogeneous plastic mass is obtained.

Special attention When producing foam concrete, attention should be paid to the quality of mixing of the components. Only uniform distribution of cement in the sand will allow you to obtain optimal quality foam concrete. After all of the above, using a foam generator, a certain portion of foam is fed through a hose into the mixer, where it is mixed with a pre-prepared cement-sand mixture for 120-180 seconds. If you control the specified density in production, you can quite easily obtain the required compressive strength of foam concrete. Cast foam concrete, like any other concrete that is bonded with cement, needs to create a temperature and humidity regime. This is done, on the one hand, to maintain the process of cement hydration and strength gain, on the other hand, it reduces the exothermic temperature and prevents cracks from forming in the concrete. Because of this, it is recommended to cover the mixture immediately after laying the mixture. concrete surface plastic film.

Video how to do it:

Areas in which foam concrete is used

This material is used on roofs and floors as heat and sound insulation. Foam concrete itself is not construction material. In addition, it is used for tennis courts and filling voids in brickwork underground walls, insulation in hollow hollow blocks and any other infill where high insulating properties are required. The areas of use of foam concrete are: production of building blocks for low-rise construction of houses and partitions, monolithic house construction, thermal and sound insulation of walls, floors, slabs, ceilings, filling of void spaces.

Foam concrete is a popular building material that has good heat and sound insulation characteristics. Independent production foam concrete allows you to reduce material costs several times. 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 opportunity 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 are improving performance characteristics 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, but construction works are carried out even in earthquake-prone areas.

5. Speed of installation.

Using foam concrete as building material for the construction of 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 overall cost of the building, as the cost of purchasing heat and sound insulating materials is 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.

Walls made of foam concrete 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 must be reinforced in order 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 external finishing solves quickly this disadvantage. 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. Using this material, old buildings are reconstructed and repaired, their number of storeys is increased and the sound insulation of floors is improved.

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 of the highest density 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. The use of an 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 Device efficiency 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 durable and even surface that is 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 individual production foam blocks, thirty forms 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 of the required size and shape. 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 glue 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 turn out to be of the 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:

When constructing houses recently, homemade ones made from aerated concrete and foam concrete are increasingly being used.

Foam concrete is ordinary cement mortar, which is mixed with a small amount 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 have soundproofing and heat-insulating 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 (can be cut, sawed and drilled well), without special 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;
the blocks made from it are lightweight, their sizes allow you to save on mortar and carry out construction work at a faster pace.

Manufacturing Equipment

Foam concrete is produced by foaming and the concrete mass is filled with air bubbles. This makes the material lightweight, sound and heat insulating.

Existing technologies make it possible to produce high-quality foam concrete 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. Faucets different sizes and types with a drum with a capacity of 60 and up to 240 liters can be purchased at construction equipment stores. With their help they get concrete mortar. 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 lined with 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, a suitable room under the roof will be required. The temperature in it should be no 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;
into the resulting concrete mixture a foaming agent is introduced 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.