Aerated concrete is a building material. A stone created artificially, having spherical air pores. Beginning entrepreneurs think about creating a business, which includes the creation and sale of a product. But first you need to draw up a business project for the production of aerated concrete.
Nowadays, this project is in great demand. Beginning entrepreneurs are interested in how to launch this project to create high-quality material. It is attractive because the payback period is short, because many people use this type of stone in construction. Aerated concrete parameters: 10*30*60 cm and 20*30*60 cm. It has a large number of positive qualities:
- unpretentiousness to the foundation of the house, high strength, low weight;
- retains heat well, does not allow cold to pass through, and protects from external noise;
- easy to install, allows you to quickly erect a structure;
- easy to process, achieve the desired shape of the material;
- environmentally friendly material;
- earthquake-resistant;
- fire-resistant stone, with high fire safety.
Therefore, consumers choose this product. The product contains the following components:
- cement;
- sand (quartz is perfect);
- gas generator (this can be: aluminum powder, paste, lime, ash, gypsum).
Stages of organization
Determine how large your enterprise will be and what type of products you will produce. There are two types of material production:
- autoclave;
- non-autoclave.
In order to produce aerated concrete using method 1, you need to harden it in an autoclave with steam. To make the material using method 2, it is necessary to dry the aerated concrete using heating.
What you will need:
- rented or personal premises;
- line for the production of aerated blocks from scratch;
- workers.
From the data on what volume of production will be and what type of material is suitable, you can determine the area of the premises, the amount of equipment and the number of employees.
If you plan to produce up to 30 meters of cubic blocks per day and work an 8-hour shift, a room of 70 square meters will be enough for you. When producing 100 - 150 cubic meters, working around the clock, an area of about 600 square meters will be required. It is necessary to have warehouses for storing products, although it is possible to leave blocks in the open air.
To produce 1 cubic meter of blocks you need:
With such data, it turns out that the cost is 1,500 thousand. It turns out that the minimum price for 1 cubic meter is 2,500 thousand.
Business plan for the production of aerated concrete blocks:
- registration of an organization – from 7 to 10 days;
- finding rental premises – a month before the start of the enterprise’s activities;
- purchase of equipment - two weeks before the opening;
- installation of equipment and connection - before the start of activity;
- purchase of necessary raw materials - a week before the start;
- recruitment of employees - before the start;
- Start production process– after registration papers are completed;
- finding buyers, establishing sales - from the moment work on the project begins;
- material sales;
- creation of reserves.
Search for clients
Manufacturers and buyers are pleased with the fact that the building material is suitable for any climate zone. It is usually used when constructing buildings:
- low-rise residential premises;
- industrial;
- agrarian;
- administrative;
- social.
The product is in demand both among large construction organizations and individuals with development rights.
You can sell goods to construction trade warehouses and markets. Distribute price catalogs to stores. Send business proposals to development companies. Publish advertisements for private clients.
Necessary equipment
If you have a small organization with a small capital investment, use equipment for the production of aerated concrete using a non-autoclave method (drying of the manufactured blocks is carried out naturally). In this case, you will need pouring molds and a professional mixer.
If a discovery occurs that involves an autoclave method of creation with a more powerful production line, you will need, in addition to the usual devices, an autoclave (for the purpose of increased temperature treatment). Also required:
- vibrating sieve;
- compressor;
- dispenser;
- cutting devices;
- conveyor line.
- steam generator;
A vibrating sieve is needed to sift sand. The dispenser accurately determines the amount of required components. The steam generator provides steam for processing aerated concrete blocks.
With this set, the production speed will increase, but opening will require a larger sum of money.
Based on a productivity of 60 cubic meters daily, the cost of the minimum set is 790,000 rubles. The cost of delivery, VAT of installation, setup and connection of equipment to utilities is not taken into account.
Costs and profits
You will spend three months launching the business; you should start thinking about opening it in early spring. The size of your investment during this period will be equal to 4,378,000 rubles.
Costs in rubles:
All this is required to open a business. Every month you will spend certain amounts in rubles:
It turns out about 1,100,000 rubles every month.
Profitability at a high level. Payback period from 4 months to a year.
Possible income level
Income depends on productivity. You may have 3 predicted development options: pessimistic, realistic, optimistic.
With option 1 (loading power - 30%), your earnings are 331,200 rubles per month:
Option 2 (loading power - 60%) assumes an income of 662,400 rubles per month:
Productivity depends on you. Also influenced by the fact that the demand for this product is seasonal. It is advisable to launch production during this period and have time to sell all the goods.
Registration and registration of business
You need to register your organization in the form of “IP” or “LLC”. It is necessary to draw up a business plan for production, analyze the market situation, and identify competitors. Here step-by-step instruction:
- Summary of the enterprise;
- Marketing project;
- Organizational plan;
- Financial plan;
- Risk analysis.
If you understand that you cannot understand all the intricacies of the registration process, we advise you to contact specialists.
Costs and payback period
You will need to invest about 5 and a half million in the project. With an average capacity of aerated concrete production (30 - 60% of potential), the payback period for your production will take from 7 to 12 months from the start of the production line. It is possible that this period will be reduced, provided that the material sales reach 90%.
Disadvantages and advantages of this business.
The positive aspects are:
- a sought-after product, the demand for which is constantly growing;
- low production costs;
- high profitability, short payback period;
- not a very large amount of initial capital is required;
The shortcomings are noted as follows:
- growing and serious competition in this market;
- demand for goods is seasonal;
- the need for storage facilities;
- you need to constantly attract new customers.
Each region has its own specific case. When opening production, rely on data from your region.
Useful video
First, get to know your market. It is advisable to find buyers in advance; this will prevent the finished product from sitting idle.
Organize your enterprise in the spring, so that by the time construction work usually begins, the vases will have a supply of the finished product.
If you are going to produce non-autoclaved concrete up to 10 cubic meters of material daily, then you will spend about 200,000 thousand on equipment, if from 25 - 30 cubic meters, then about 450,000 thousand, if 75 - 150 cubic meters, then from 2,000,000 thousand . Decide how much product you can sell in your region. From this data, decide how much to produce.
It is profitable to create an organization for the production of aerated concrete. An aspiring entrepreneur needs to expand his knowledge in this area. Follow all instructions in your business plan before opening your business. If you organize your project correctly, success awaits you!
How to start producing aerated concrete: business plan, financial calculations
5 (100%) votes: 1As you know, in our time “simple” concrete, i.e. without various additives and additives that improve its properties, it is practically not used. Various additions change and improve the structural properties of concrete blocks and make them suitable for use in the most various designs. Therefore, the topic of production of foam and aerated concrete is relevant.
First of all, concrete blocks require high levels of thermal insulation and soundproofing. Sometimes the production of such concrete blocks is successfully combined with other productions and waste from them is used - for example, expanded clay, foam plastic, mineral wool, wood and even various slags are added to concrete before pouring into block forms. This leads to the formation of concrete blocks with new properties - for example, buildings built from them lose less heat in winter and do not overheat in summer; in addition, due to the reduction specific gravity the load on the foundation is significantly reduced, etc.
But combining two industries at the same time - for example, a sawmill and a cement plant - turns out to be quite difficult. Therefore, in the construction industry, special foam or gas is used to produce cellular concrete.
Hence the name of two materials that are currently in great demand: aerated concrete And foam concrete.
How are aerated concrete and foam concrete produced?
Aerated concrete is produced by introducing special substances into the cement mortar that cause the process of gas formation, or simply release gas during a certain chemical reaction. The main component in this case is aluminum powder, which reacts with the products released during cement hydration. From a chemical point of view, hydrogen is released, causing the formation of pores in the cement mortar. Visually, it looks similar to dough after yeast has been added to it. The cement mass begins to increase in volume and after it hardens, porous concrete is obtained.
Foam concrete is produced by mixing cement mortar with special foam prepared in advance. In this case, foam bubbles that contain air are evenly distributed throughout the entire volume of the mixture. The effect of porosity, like the previous material, remains after hardening.
Typically, both types of concrete blocks are used for construction: load-bearing walls are made from stronger aerated concrete blocks. They bear the main structural load. Foam concrete blocks, which are 20-25% cheaper, are used for non-load-bearing partitions and bulkheads.
As you can see, it is most advisable to produce both types of concrete blocks.
Material costs for launching a mini-plant for the production of aerated concrete and foam concrete
Let's consider the investments required to open joint foam concrete and aerated concrete equipment.
A mini-plant for the production of foam concrete will cost, depending on the capacity, i.e. the volume of concrete produced is 105,600-283,800 rubles. (capacity 10 cubic meters - 30 cubic meters per shift). For the production of aerated concrete - 29,800-85,000 rubles. (capacity 12 cubic meters - 50 cubic meters per shift).
In addition, for a foam concrete mini-plant you will need a foam generator (27,800 rubles) and a compressor (37,800 rubles) and a peristaltic pump (57,700 rubles)
Molds for the production of concrete blocks of various sizes will cost from 28,000 rubles. up to 40,000 rub. (1 cubic meter of mixture is pumped into 1 mold, so, for example, with a plant capacity of 10 cubic meters of molds, 10 pieces are required).
Total:minimum investment 538,700 rubles, maximum - 1,332,100 rubles.
- 1 cu. m of foam blocks costs about 3,000 rubles.
- 1 cu. m of gas blocks costs about 3,600 rubles.
Consumables (per 1 cubic meter):
- Foam concentrate 75 rub. for 1 kg (for foam concrete)
- Aluminum powder 500 g, 105 rub. for 1 kg (for aerated concrete)
- Sand 300 kg - 350 rub. per cubic meter (1.3 t)
- Cement - 100 kg (2 bags for 189 rub.)
As you can see, material costs are insignificant: about 540 rubles. per 1 cu. m of foam concrete or 520 - for aerated concrete.
How much can you earn from producing concrete blocks?
Gross profit per 1 cubic meter m of foam blocks is equal to 2460 rubles, gas blocks - 3080 rubles. If we take production equal to 10 cubic meters. m per day (5 - foam concrete and 5 aerated concrete), the monthly gross profit is equal to about 665,000 rubles.
Net profit less wages workers, utility payments(the production of concrete blocks is quite water and electricity intensive) will be at least 30-35% (about 200-220 thousand rubles) per month.
It turns out that if you pay half of the net profit, for example, for equipment purchased in installments for the production of concrete blocks, it will pay off in six months, and when purchasing the most powerful equipment, the payback will be even faster - about 3-4 months.
This will happen due to higher production volumes. In general, it is more advisable to purchase the most powerful equipment: with a price difference of 2.5 times compared to the lowest-power equipment, it produces 5 times more products.
In addition, with proper business development, it will also be possible to produce, for example, paving slabs and decorative (multi-colored) blocks, which cost much more than usual.
Videos about the production of aerated concrete and foam concrete
A business idea for the production of aerated concrete blocks with a description of the technology for their production and a feasibility study for the implementation of a project to launch a production line with a capacity of 60 m3 per day.
Descriptive part
The production of aerated concrete is the process of manufacturing structural and thermal insulating blocks or a monolith for partitions and load-bearing walls made of porous (cellular) concrete. The characteristics of a material such as aerated concrete are attractive to both the end consumer and the manufacturer.
Products and their parameters
There are aerated concrete made from cement, produced using a non-autoclave method, and aerated concrete made from lime, the blocks from which are made using an autoclave hardening method. The difference between them is not only in the components and raw materials for production, but also in the specifics of the material - non-autoclaved aerated concrete is used for monolithic construction, and blocks made from it shrink significantly, so their production is not recommended.
Aerated concrete blocks come in two main shapes - rectangular and U-shaped (suitable for window and door openings). The size of autoclaved aerated concrete blocks is determined by the molds used for pouring and must correspond to typical values:
- For rectangular blocks: length - 625 mm, height - 250 mm, and standard width - 100, 150, 200, 240, 300 or 400 mm.
- For U-shaped: length 600 mm, height - 250 mm, width - 200, 240, 300 or 400 mm.
Individually, it is possible to use other standard sizes, and simple processing allows you to implement any design solution.
The choice of aerated concrete as a building material by consumers is based on its properties such as:
- Great strength, light weight and undemanding foundation;
- High level of thermal insulation, first-class sound insulation and high-quality energy saving;
- Fire resistance and Fire safety;
- Easy to install and high speed construction;
- Convenience of giving the desired shapes, ease of processing and application finishing materials;
- Environmentally friendly and free of harmful substances;
- Seismic resistance and minimal load on the building structure.
In terms of these parameters, aerated concrete is significantly ahead of other building materials - wood, ordinary concrete, and even technologically similar foam concrete.
Production cycle
The raw materials for the production of aerated concrete are universally available cement or lime, sand, water, as well as a special reagent for gas formation in the working mixture (a suspension of aluminum dust or paste). Slag or gypsum is rarely used.
The production technology of aerated concrete blocks includes the following stages:
The technological process involves not only a concrete mixer, but also special molds for casting blocks (there is an option with cutting a mass of aerated concrete into blocks of the required size), associated equipment for transporting, processing and supplying raw materials (vibrating sieve, dispensers, hydraulic carts).
Sales policy
Aerated concrete is used as a building material in all climatic zones, mainly in the construction of low-rise residential buildings, as well as in other types of housing construction and in industrial and agricultural construction, construction of administrative and public buildings. Ready-made blocks or monolithic castings are in demand both among private developers and construction companies.
Sales channels for aerated concrete blocks:
- Construction trade bases, markets and shops (distribution of price lists);
- Directly from development companies (newsletter commercial offers);
- Private clients (publication of advertisements).
When planning sales, it is necessary to take into account the seasonality of construction, the productivity of the equipment used and the specifics of manufacturing aerated concrete - the blocks are fully ready a month after the start of production.
Features of aerated concrete production
During production, such qualities of building materials as efficiency and low cost, low weight with increased strength, simplicity of manufacturing technology, safety and ease of processing are manifested. All this makes the costs of producing aerated concrete minimal, and the production process itself profitable.
The advantages of this type of activity include:
- High demand in this market segment and demand for products;
- Low production costs and high profitability;
- High level of profitability and quick payback;
- Relatively small amount of required starting capital.
Disadvantages of aerated concrete production as a business:
- Great competition in the building materials market;
- Seasonality of demand;
- The need for extensive warehouse space;
- The need to regularly attract new clients.
When deciding to open aerated concrete production, one should take into account the specifics of the region and established traditions in individual housing construction.
Calculation part
Feasibility study *
The optimal time for opening a line for the production of aerated concrete blocks is the beginning of spring (March-April), then it is possible to create a certain reserve for the active construction season finished products and in the first year recoup the costs of starting a business.
Table 1
| Stage name | Description of actions | Duration of the stage |
|---|---|---|
| You can register an individual entrepreneur or LLC | 7-10 days | |
| A workshop for the production of aerated blocks, warehouse space and staff premises are required | 2-4 weeks before production starts | |
| Purchase of equipment | Scroll necessary equipment is given below | 1-2 weeks before scheduled start of work |
| Installation and connection of equipment | It is necessary not only to assemble and install the equipment, but also to connect it to the electrical network | Before production starts |
| Purchase of raw materials | Purchase and delivery of sand, cement or lime, blowing agent, additional additives - plasticizer | 1 week before production starts |
| Hiring 2-3 workers to maintain aerated concrete production line | Immediately before production begins | |
| Starting the production process | Provided all previous steps are completed | After receiving registration documents |
| Finding clients and establishing sales | Calculation of cost and creation of a price list, preparation and distribution of commercial offers and advertisements | |
| Sales of finished products | Logistics solutions (vehicle rental, sale for pickup), organizational arrangements - accounting operations and preparation of documentation | During the entire period of work on the implementation of the project - from 23-30 days from the start of the first production cycle |
| Creating a stock of raw materials and finished products | Purchase of raw materials and storage of finished aerated blocks, taking into account seasonality of demand | Throughout the entire period of work on the project implementation |
table 2
| Month 1 | Month 2 | Month 3 | Total | |
|---|---|---|---|---|
| Business registration | 10 000 | - | - | 10 000 |
| Selection of premises for rent and payment of the deposit | 240 000 | - | - | 240 000 |
| Purchase of equipment | 909 000 | - | - | 909 000 |
| Delivery and installation of equipment | 150 000 | - | - | 150 000 |
| Creating a stock of raw materials for production | 800 000 | 800 000 | 800 000 | 2 400 000 |
| Recruitment and employment of workers | - | 117 000 | 117 000 | 234 000 |
| Start of aerated concrete production | - | Launch production | - | - |
| Sales and organizational expenses | 95 000 | 95 000 | 95 000 | 285 000 |
| Total | 2 204 000 | 1 012 000 | 1 012 000 | 4 378 000 |
All cost items presented in the table make up the overall composition of capital costs, as well as the initial operating costs for starting production and one-time investments that will need to be spent on start-up capital.
The structure of one-time costs for creating a mini-plant for the production of gas blocks is presented in the table, broken down into capital costs and investments in working capital for the period the enterprise reaches self-sufficiency (the first two months from the start of production).
Table 3
| Stage name | Cost of events, rub. |
|---|---|
| Capital investments | |
| Business registration | 10 000 |
| Purchase of capital equipment | 789 000 |
| Purchase of additional equipment (warehouse carts, racks) | 120 000 |
| Total capital expenditures: | 919 000 |
| Working capital | |
| Delivery, installation and connection of equipment | 150 000 |
| Payment of rent deposit for 3 months | 240 000 |
| Attracting personnel and paying labor for the first two months of operation of the mini-plant | 234 000 |
| Formation of a three-month supply of raw materials | 2 400 000 |
| Expenses for organizing work for 2 months (advertising, communications, commercial payments, bank commissions, mandatory deductions and taxes) | 150 000 |
| Warehouse and transport costs in 3 months | 285 000 |
| Total working capital: | 3 459 000 |
| Total investments: | 4 378 000 |
After the preparatory period and the first two months of work, it will be necessary to regularly incur operating expenses for the smooth implementation of ongoing activities.
Table 4
| Items of current expenses | Contents of costs | Amount, rub./month |
|---|---|---|
| Rental of warehouses and production premises | 200-400 sq. m. for 200-400 rubles. per sq.m./month | 80 000 |
| Payroll | Salary + insurance premiums and contributions to extra-budgetary funds (2-3 people) | 117 000 |
| Raw materials | 8,000 - 15,000 rubles/t - for sand, cement; 55,000 - 120,000 rub/t - reagents and plasticizers | 800 000 |
| Org. expenses and other expenses, including: | 95 000 | |
| Transport and storage costs | 45 000 | |
| Account maintenance and bank fees | 2 500 | |
| Electric energy | 5 rub./kW * 10 kW/hour * 8 hours/cm* 23 shifts | 9 200 |
| Advertising | 5 000 | |
| Connection | 3 000 | |
| Taxes | 10 000 | |
| Other (consumables) | 20 300 | |
| Total: | 1 092 000 |
It is difficult to save on payroll, rent or raw materials; you can only minimize organizational costs, which do not exceed 9% of the total costs. For this reason, the optimal solution is to take care of increasing income rather than minimizing costs.
What equipment is required to start a business?
For a small enterprise with limited initial investments, it is recommended to use equipment for the production of aerated concrete using a non-autoclave method - with natural drying of the prepared blocks. In this case, you can get by with a special mixer and pouring molds. The line for the production of higher-capacity aerated blocks uses an autoclave manufacturing method in order to save space for storage and speed up the output of finished products.
Additionally, you will need to purchase an autoclave for accelerated heat treatment. The presence of a vibrating screen, dispensers, compressor, and conveyor line will increase the production speed and allow automation of the process, but this will increase the cost of the production complex.
Table 3
| Name | Purpose | Price, in rub. |
|---|---|---|
| Component dispenser DZ-K-01 | Precise automatic weighing and dosing of working mixture components in the production of aerated concrete | 168 000 |
| Gas concrete mixer "STROM-1000" | Preparation of aerated concrete mixture | 89 000 |
| Cutting complex URB-1-14 | Cutting aerated concrete into blocks of standard sizes | 420 000 |
| Vibrating sieve VS-3 | Sifting sand | 42 000 |
| Steam generator | Steam supply for processing aerated concrete blocks | 46 000 |
| Water dispenser DZ-V-01 | Accurate dosing of liquid when added to the working mixture | 24 000 |
| Total cost of basic equipment: | 789 000 | |
The minimum set of stationary equipment for the production of aerated concrete blocks, with a capacity of 60 m3 per shift, will cost 789,000 rubles excluding delivery and VAT; installation supervision, adjustment and connection of the equipment to utilities are paid separately.
How much can you earn from this type of business?
Calculation of revenue and profitability of the production of gas blocks using the specified equipment is given in three options: pessimistic (using 30% of the capacity), realistic (using 60% of the equipment’s capacity) and optimistic (90% of the potential).
Table 4
Table 5
Table 6
Table 7
Even with potential capacity utilization of only 30-60%, it is possible to recoup all initial investments in the gas block production business within one year - within 7-12 months from the launch of the production line. It is important not just to take into account production volumes, but to evaluate sales opportunities - if 90% of the potential volume of produced blocks is sold, you can return all initial costs within the 5th month.
Aerated concrete is used as a building material in the construction of residential and commercial premises. Main advantage of this material is that the concrete blocks are formed and hardened before they are delivered to the job site. During production, hydrogen gas creates voids in the concrete, thereby aerating the block. Aerated concrete occupies a major share in the global market for the production of building materials, which makes it very profitable for production. It occupies more than 75% of the concrete block production market due to its size, ease of production and widespread use in construction.
If you decide to organize a business for the production of aerated concrete, first of all you will need space for production. Making aerated concrete with your own hands is a very complex process that is not suitable for home use. In any case, you will need to organize a factory or manufactory. For large plant(production volume 300,000 m3 per year) a logistically advantageous location with an area of 25,000 to 30,000 m2 is required. Ideally, the site should be about 150 m wide and 200 m long.
The production workshop should have an area of about 6000 m2 and a height of 9 to 12 meters. Directly next to the production hall there should be bunkers for sand, burnt lime and cement. Storage facilities must be large enough to accommodate raw materials, typically for two to three daily productions within a 24-hour period.
Budget for aerated concrete production business
Investments in an aerated concrete factory, including construction and infrastructure measures, range from 5 to 20 million rubles. Regional markets in Russia are almost not supplied with aerated concrete of the required quality, so you will always have sufficient demand for the product. To meet this demand, the plant will need to operate around the clock for at least 300 calendar days per year. Assuming that raw material costs and selling prices are based on market and general indicators, the return on investment for the entire plant can be projected in approximately 38 to 48 months. This fact will help you navigate the loan amounts for your business.
Given the relatively low investment volumes and high productivity, efficiency technological process and the long economic life of the aerated concrete plant, one cubic meter of aerated concrete costs practically nothing. Thus, you can receive high percentages from sales of finished building materials.
Properties of autoclaved cellular concrete
Autoclaved aerated concrete is a non-flammable lime-based cement building material that is entering new global markets. In our country, aerated technologies have been developed for about 40 years. Every year the technical skills of production become more and more advanced. Aerated concrete has the characteristics of light bulk density, good thermal insulation properties and sound absorption, certain strength and manufacturability.
The advantage of this material is that it ensures comprehensive utilization of industrial waste, curbs pollution environment, creating socio-economic benefits. Aerated concrete is an ideal alternative to traditional clay brick walls. It is a lightweight building material produced in an autoclave from a mixture of siliceous materials such as ground sand or fly ash and a binder such as Portland cement or lime.
Aerated concrete blocks are equally suitable for residential construction, multi-storey buildings, commercial and industrial production. The autoclaved aerated concrete sector of the construction industry is currently undergoing a huge growth cycle. When produced, aerated concrete reduces the use of additional material and minimizes waste and pollution.
Advantages of aerated concrete production
The main advantages of autoclaved aerated concrete over other facing materials are its good strength-to-weight ratio, its workability and fire resistance. The autoclave industry will witness phenomenal growth in the near future. It is estimated that by 2025, about 66% of the world's population will live in urban areas on 7% of the land, meaning that urbanization will occur on a small portion of the land. This will require taller buildings and the use of high-strength aerated concrete.
Raw material procurement plan for aerated concrete
Aerated concrete is made from raw materials: quartz sand, lime, cement, gypsum (anhydrite), aluminum powder or paste and water. Technical requirements The requirements for raw materials in a modern plant are very high. Sand that exactly matches the mix design specifications is almost never available. Accordingly, sand grinding and conditioning of the reverse suspension are required. Required ingredients include:
- Water: 250-300 liters per cubic meter of aerated concrete;
- Portland cement: 260-320 kg per cubic meter of aerated concrete;
- Filler: 250-300 kg per cubic meter of aerated concrete;
- Chemical additives: 1-3 kg per 1 m3 of aerated concrete;
- Gas generator: 0.5-0.7 kg per 1 m3 of aerated concrete.
The cost of materials depends on the region and is calculated individually.
Aerated concrete production technology
Equipment for aerated concrete requires high standards mixing and dosing of aggregates, the fermentation process and control of each stage of production. Aerated concrete plants represent advanced technological machines, designed according to the specific requirements of clients. This approach allows you to get comprehensive solutions to provide highly efficient, optimized processes that ensure consistent quality of the final product.
Kneading process
The aerated concrete block production line begins with the mixing process. Precisely measured raw sand and the required amount of water are fed into a wet ball mill, where the raw sand is processed into a sand slurry. The consistency of the sand slurry is determined precisely in terms of the density of the sand slurry and the fineness of grinding. The productivity of the aerated concrete mill is adapted to production capacity plant, taking into account the required maximum density of aerated concrete. The grinding process itself is carried out using steel balls. After the grinding process, the sand slurry is pumped into sand slurry tanks for storage. Built-in stirrers serve to maintain optimal consistency.
Additives to the mixture
Everything extra raw materials - lime, cement, gypsum (anhydrite) and aluminum powder/paste - stored in accordance with safety regulations, partially pre-mixed, weighed and fed into the mixer along with sand slurry and water. The mixer itself is equipped with all the necessary dosing and weighing devices and a device for measuring temperature. The mixer is installed above the filling device.
Feeding the mixture into the mold
When the mixing process is completed, the casting device feeds the mixture into the mold. If necessary, the mixer as well as the filling pipe can be automatically rinsed with water. The rinse water is either collected in a rinse water tank or used to prepare a return slurry.
Fermentation
Equipment for the production of aerated concrete includes a transport platform or conveyor. The transport platform moves the filled mold into a closed and heated pre-curing area, also called the fermentation area. Due to the alkaline reaction of aluminum in suspension, many small bubbles form in the compound. At the same time, the cake begins to harden. After a waiting time of 2.5 - 4 hours, the specified cutting force is achieved. The waiting time depends on the temperature in the fermentation zone, as well as the quality of the raw materials used and the selected recipe.
Next, the form is removed from the aerated concrete mass. This procedure consists of several stages. First, the mold is grabbed by a lathe and tilted 90. Then the mold with a side plate acting as a support plate is placed on the cutting machine. Finally, the form is automatically removed. The advantage of this method is that the aerated concrete cake remains on the side slab and can thus be passed through individual cutting line stations.
Mold assembly and lubrication
The empty mold is transported to the return track where the side plate is inserted. Then the mold is tilted 90 degrees so that the fill hole is at the top. The complete mold is placed on a conveyor track leading to the mixing plant. Necessary lubrication of the mold before refilling can be done manually or automatically using newest generation Masa oil distribution systems.
Cutting line
The cutting line includes several stations that are installed above the trench to collect cutting waste. On pre-installed rails, the cutting machine moves the side plate with fresh aerated concrete mass through the pre-cutting unit. Since the aerated concrete block is vertical, short cutting wires can be used. This allows you to make high-precision geometric cuts that meet modern European standards. Optimal coordination of the individual components ensures a smooth and efficient production process.
Transport workshop and tilting table
In the transport workshop, the side plate with the cut aerated concrete cake is placed on an inclined table. The aerated concrete mass is immediately turned 90 and placed on the hardening grid. In this case, the side slab is separated from the aerated concrete cake. The side plate is returned to the shop for precision molding, and along the way the so-called bottom cut is removed. This bottom cut is also recycled and returned to the aerated concrete manufacturing process. The aerated concrete mass, which is on the hardening grid, is transferred to the hardening machine. When three aerated concrete blocks are stacked on top of each other, the hardening machine is transferred to the autoclave platform.
Autoclave
The main reason for the impossibility of making aerated concrete at home is that it is impossible to install a sufficiently powerful autoclave at home. Aerated concrete hardens under steam pressure in special sealed pressure vessels, thereby achieving its final strength. The steam pressure is about 12 bar, the temperature is about 192 C.
The curing procedure is precisely defined. Curing time depends on the density and nature of the open cells of the aerated concrete cake. Typically curing time is 10 to 12 hours. Various stagesautoclavingcan be determined individually in the autoclave control system. The complete hardening process is carried out automatically and recorded continuously. The steam used for the hardening process in autoclaves is generated in the steam boiler room. Typically, high-power steam boilers running on gas or oil are used to generate steam.
Transportation of hardening mesh
When the hardening process is completed, the aerated concrete blocks are ready for use. From the transport platform, the hardened aerated concrete block is transported to a folding table by a second transport plant. There it tilts 90 degrees and moves to the separating machine.
Separating machine and packaging
Depending on the raw materials used, aerated concrete blocks sometimes stick to each other. Therefore, we recommend using a separating machine for hardened blocks. The main advantage is that delicate products with low density and low wall thickness can be carefully separated. Compared to other systems, this procedure significantly reduces the failure rate.
After this, the transport conveyor moves the aerated concrete blocks into the block moving device. High quality aerated concrete block requires smooth handling. Therefore, the finished product must be packaged in such a way that it is protected from dirt and moisture before it is removed from the factory. Depending on the plant concept, the packaging process can be carried out automatically or semi-automatically.
Production of aerated concrete blocks- business plan
The materials required are sand, burnt lime, Portland cement, gypsum, water and aluminum powder or paste. To produce 1 m3 of autoclaved aerated concrete, about 500 kg of these materials are required. With the exception of aluminum, all other materials must be on hand in sufficient quantity and quality.
Transportation costs for raw materials partially exceed the purchase price of the raw materials themselves. Therefore, when choosing a location for a plant for the production of autoclaved aerated concrete, it is important to find the logistically optimal location in terms of the distance from the source of raw materials to the plant and the intended delivery destinations of the finished construction product. There is no ready-made solution for this; Each investment must be individually reviewed and assessed.
Here we can add that logistics costs greatly depend on the type of transport. Experience has shown that this vessel (including canal vessel) is generally the most cost-effective means of transporting broken lime.
Legal compliance and qualified personnel
Machines and mechanical equipment must comply with local legal requirements in virtually all sales regions. This applies to workplace safety, environmental protection, energy efficiency and the construction technology used. In addition, construction products manufactured by machines must be approved locally. Special attention focuses on safety and protection from cold, heat and noise.
Finding qualified personnel or funds to train personnel on the production site is of great importance for the investor. This applies equally to workers, technical management, and administration and sales personnel.
Conclusion
Do not forget that the aerated concrete you produce must fit into the climatic and cultural environment of your region. For example, in Romanian countries on the Mediterranean Sea, traditional building material is a natural stone, as it is part of the culture in this region. This is why autoclaved aerated concrete has never had much demand in these regions. Before starting production, it is necessary to analyze the construction market.
DIY productionaerated concreteand foam concrete.
During the construction process, two types of concrete blocks are used - foam concrete and aerated concrete. The production of load-bearing walls is associated with the production of durable aerated concrete, since such blocks bear the main load of the entire structure of the structure. Cheaper foam concrete blocks, the cost of which is 20-25% lower, are used for installing non-load-bearing bulkheads and partitions. From this we can draw the corresponding conclusion that the production of both types of blocks is equally advisable.
One block made of cellular concrete can replace 30 bricks, so it weighs less than 30 kg. It should be taken into account that aerated concrete blocks, which are lightweight and easy to process, allow you to build houses without the use of special equipment, that is, lifting equipment, tower cranes and so on.
Thanks to these properties, aerated concrete can be one of the most commonly used materials in the construction of low-rise housing, as well as country houses, private buildings, etc. The popularity of this material is confirmed by the dynamics of growth in its production and sales volumes.
Equipment for the production ofaerated concrete.
It should be noted that on this moment on domestic enterprises There are no developments of solutions related to the automated production process with low cost of non-autoclaved types of aerated concrete, and import suppliers offer very expensive ones.
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In order to produce aerated concrete blocks in a semi-automatic way, which will have a productivity of 12-21 m3/day on the used aerated concrete installations, it is necessary to ensure the availability of:
1. “Aerated concrete” installations with a certain productivity;
2. Vibrating sieve with a mesh size of 3 mm;
3. Cassette metal molds used for the production of block products of the established size 600x300x200 mm;
4. Petrochemicals, which involves the use of:
a) complex chemical additive - gas-forming agent;
b) choice of hardening accelerator;
5. Additional equipment, as well as chemistry:
a) hydraulic trolleys - 1-2 pcs. (up to 2 tons);
b) substances for lubricating and washing off molds;
c) multi-hose dispensers for supplying cement and sand (one for cement and one for sand), or separately for cement and sand, two for each installation. 
Price about 18,000 rubles.
Production technologyaerated concrete.
The production of aerated concrete involves a very simple technology, which includes several main stages.
The main part of technology.
This group of cellular concretes is characterized by the presence of a cellular structure. Small volume weight cellular concrete is ensured by the presence of bubbles filled with gas and occupying up to 85% of the total volume of the product.
To prepare the concrete mixture, lime, water, quartz sand and cement are used, which are mixed using an aerated concrete mixer. Stirring takes 4-5 minutes, after which it is necessary to add a little aqueous suspension of aluminum powder, which can react with the lime substance, to the prepared mixture. As a result, this reaction occurs with the formation of hydrogen, which fills numerous pores or bubbles of the raw material, 0.5-2 mm in size, which evenly penetrate the entire porous material.
After the suspension with aluminum paste is added, the mixture is quickly poured into prepared metal containers, where the process of swelling of the concrete mass should take place. These chemical reactions can be accelerated by vibration loads, which also help the entire mass of the semi-finished product to set and harden faster. After aerated concrete reaches the required stage of initial hardening, irregularities are cut off from the surface of the solid mixture using wire strings. After this, the remaining mass is cut into blocks of equal size. The resulting aerated concrete blocks are subjected to heat treatment using an autoclave. After this, the blocks are calibrated with a special milling device.
Autoclave processing aerated concrete.
To improve the properties of aerated concrete, autoclaving is used. Formed and cut aerated concrete blocks are placed in autoclave chambers, where the blocks are processed for 12 hours under high pressure conditions (12 kg/cm²) using saturated water steam at a set temperature level of 190°C.
The autoclave hardening process makes aerated concrete more durable, which allows for less shrinkage, and also ensures a more uniform structure in the blocks. This type of aerated concrete, autoclaved, is widely used in many areas of construction due to its sound and heat insulating properties. The level of thermal conductivity coefficient of such aerated concrete is 0.09-0.18 W/(m°C). This thermal conductivity of products made from autoclaved aerated concrete, when used taking into account Russian climatic conditions, allows the construction of single-row walls that have a thickness of 375-400 mm. In this case, the use of additional insulation is not required.
Aerated concrete can also be produced using a non-autoclave method.
If the production of aerated concrete is carried out using a non-autoclave method, then its mass hardens when natural conditions are created. This type production will not require the use of modern high-tech equipment, since it can be produced independently and at home, but its strength will be minimal.
Non-autoclaved types of aerated concrete have a shrinkage of 3-5 mm/m during operation, and autoclaved ones have a shrinkage of 0.3-0.5 mm/m. Autoclaved aerated concrete has a strength of 28-40 kgf/m², and non-autoclaved aerated concrete has a strength of 10-12 kgf/m².
Conventional aerated concrete is produced more rarely than autoclaved concrete. It can also be made at home, since there is no need to buy complex equipment in this case.
Material costs for launching a mini-production plantaerated concreteand foam concrete.
In order to open a joint production of foam concrete and aerated concrete, some investments may be required, the calculation of which is presented below.
The mini-plant itself for the production of these types of concrete can have a cost of 105,600 - 283,800 rubles, which depends on the capacity or volume of production of concrete products, which will be 10 - 30 cubic meters. m per shift. For the purpose of producing conventional aerated concrete - from 29,800 to 85,000 rubles, with a capacity of 12 - 50 cubic meters. m in one shift.
To produce foam concrete, you will need a foam generator costing 27,800 rubles, as well as a compressor - 37,800 rubles. In addition, the mini-plant will use a peristaltic pump, the cost of which is 57,700 rubles.
During the production process, forms for concrete mass will be used, having different sizes - 28,000-40,000 rubles. At the same time, 1 cubic meter of mixture can be pumped into 1 mold, and if the plant capacity is 10 cubic meters, then 10 molds will be needed.
Total: the cost of the minimum investment will be 538,700 rubles, and the maximum - 1,332,100 rubles.
A foam block of 1 cubic meter will cost 3,000 rubles.
Zazoblok 1 cubic. m - about 3,600 rubles.
Cost of consumables per 1 cubic meter. m will be:
1. Foam concentrate - 75 rubles per 1 kg - for foam concrete;
2. Aluminum powder (500 gram packaging) - 105 rubles per 1 kg - for aerated concrete;
3. Sand (300 kg) - 350 rubles per cubic meter - 1.3 tons;
4. Cement (100 kg) - 2 bags at a price of 189 rubles.
From the calculation data it is clear that material costs are insignificant - about 540 rubles per 1 cubic meter for foam concrete, or 520 rubles per 1 cubic meter for aerated concrete.
Expenses and income.
The process of producing aerated concrete is very profitable. The cost of 1 cubic meter will be 1,800 rubles, and the retail price will be 2,500 rubles. Therefore, when producing and selling 250 cubic meters of block products per month, the level of net income will be 175,000 rubles. At the same time, the payback period for investments will be 1-2 years.
During the implementation of seasonal construction work in the period from May to October, the demand for aerated concrete blocks becomes maximum, as private construction occurs more intensively. Preparatory work, related to the start-up of production should occur in the off-season period. It would be useful to have small stocks of concrete products in warehouses during this period; therefore, it is better to start production in March-April. Fast payback capital investments will be provided subject to these conditions, which will accelerate the receipt of profits in the form of cash.
If you have a private business not in rented premises, but in your own premises, production costs will be minimal. To produce 1 m3 of concrete, it will take about 2-3 hours. During one working day, it will actually be possible to produce 2-5 m3 of products, and no outside help will be required. If the productivity is 1-2 m3 per day, then all equipment costs can be recouped in a month. When setting up a regular production process of 3-5 m3 per day, one person can make a profit of up to $3,000 every month, while the correct construction of the sales market is important. Since sales of products will affect the profitability of this business.
Can be used various ways advertising, they are all useful, for example, placing advertisements in local newspapers, handing out business cards, posting advertisements on the street, etc. In addition, you should immediately offer ways to deliver products to customers, which will also lead to successful implementation blocks. Having concluded an agreement on the provision transport services, you can subsequently receive discounts. Any developer will be pleased with the timely delivery of concrete blocks, and he will not even know where they are produced.
Video mini production of aerated concrete and foam concrete with your own hands:
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