Is it worth it to make expanded clay blocks yourself: an accurate estimate of production at home

On the Internet there are many articles and videos with the titles: "How to make an expanded clay block five times cheaper"; "DIY paving slabs"; Garage Business - Building Block Manufacturing. There are a lot of names, the essence is the same - to show a simple technology that will help save on construction sites and even earn money. But is everything as simple as the craftsmen show? Let's figure it out!

We count materials

Let's analyze the expanded clay block. Let's take, for example, the ratio of structural expanded clay concrete grade M200. For the manufacture of 1m3 blocks of this brand, 1.3 tons of materials will be needed, of which 150 kg of cement, 420 kg of sand, 720 kg of expanded clay (proportions - 1 / 2.8 / 4.8).

Today it costs:

• cement - 3 bags - 1050 rubles;
• sand - 0.42 tons - 130 rubles;
• expanded clay, fraction 5–20 mm - 0.72 tons (2 m3) - 3500 rubles.

Total: 4680 rubles (at prices of the central regions of Russia).

But the consumption of materials is designed for a full-bodied block, and if we take into account the voids, approximately 30%, it turns out that 1.3 cubic meters of a block will turn out from a cubic meter of expanded clay concrete. In the number of pieces, this will be 93 blocks. Product weight - 13.9 kg: everything is fair here and calculations can be easily verified!

Further, we divide the amount spent on materials 4680 rubles by the number of blocks - 93 pieces and we get the raw cost price - 50 rubles / piece. Such a block in central Russia costs 60 rubles apiece. The resulting savings are 10 rubles per unit. If a house, for example, needs 5 thousand. blocks, then the saved money will be 50 thousand. rubles. But that's not all.

By the way, the brand of a block with voids will not come out M200, as in monolithic expanded clay concrete with such proportions of components. The strength will drop approximately three times, and probably five times. It all depends on the equipment on which the unit will be produced.

Home production can be safely considered artisanal and if the block comes out with the M35 brand, this is already a success. And many large manufacturers, armed with professional vibropress equipment, declare the M50 brand of products, while in fact it does not exceed all the same M35. This effect is achieved due to the strict economy on cement and the violation of technology.

Equipment

We have received the raw material cost, now we need to calculate the equipment required for production.

For mini-production, there are two main types of machines:

• stationary forming blocks on pallets;
• mobile, hard-surfaced forming blocks.

The cost of such equipment is 10-30 thousand. rubles. But if a concrete platform is enough for one machine; for the second, pallets are needed, which will cost an additional amount.

For example, if a machine molds 2 blocks in one approach, and its declared capacity is 350 pieces per shift, then 175 pallets are needed for one work shift. It is not recommended to touch blocks that are not subjected to pressing (pressure by a hydraulic press) in the first two days. Thus, the stock of pallets required for the declared capacity and with a minimum number of scrap will be 525 pieces. This amount can cost as much as the equipment itself - manufacturers prefer to remain silent about this.

Another element for the production of expanded clay blocks is a concrete mixer. There is one in the store from 8 thousand. rubles, but you can completely get by with a used mixer found from cheaper ads, for example, for 4 thousand. rubles. By the way, for this money you can only buy an ordinary "pear", which will not be able to mix the solution qualitatively. In large industries, various concrete mixers are used, mainly forced, rotary or worm gear. This equipment is intended for the production of a semi-dry mortar, which is necessary to obtain high-grade expanded clay concrete.

Let's summarize the intermediate result. Now, without much difficulty, you can buy quite tolerable used equipment: for example, a mobile machine for 8 thousand rubles. and concrete mixer for 4. In general, the cost of equipment will amount to 12 thousand rubles. When purchasing equipment, the savings will be reduced to 38 thousand.

A little about labor costs

For example, we took the need for 5 thousand. blocks. The average productivity of a mini-machine will be 250 pieces per shift, that is, per day. Divide 5000 by 250 and get 20 working days; roughly speaking, one month for all cases. But, as always, there is a nuance: 5 thousand. blocks - this is about 70 tons of weight that you need to drag on yourself for a month.

Working on such a machine requires at least two people: an operator (steering machine) and a helper who interferes with the solution. As usual, no one will work for free, and for a month at the very minimum wage, you will need to pay 18 thousand to an assistant. Of course, you can bring in some kind of relative for such work, but this is fraught with production downtime.

In the best and most honest version, when a paid assistant will work, the money saved will be 20 thousand rubles. From this amount it is worth subtracting a couple of thousand for a plasticizer (to increase strength) and electricity costs. Theoretically, this option will save 18 thousand rubles. Is it worth it - you decide.

I will have the equipment and go into business!

Many hope that the equipment will work and generate income in the future. Here you can immediately dispel all dreams and say with confidence: the production of a block or paving slabs at home is a dead idea and will not bring any income.

Firstly, handicrafts are of low quality and there is no demand for them - they will not compete with factory products. Secondly, for sales you need to invest in advertising, and this will negate all "income". Thirdly, the buyer will ask for test results, receipts, other documents, and this is the registration of an individual entrepreneur and additional expenses.

The myths about the garage business are being spread by hardware manufacturers. It is profitable for them that their toy machines are bought, and what will be done with them later - they are not interested. Saving on home production is a dubious event: this time can be spent on more productive things.

What do you think, is it better to buy building materials or do it yourself? Write in the comments!

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