Self-made blocks: instruction step by step

How to master the unit of production technology at home

From this article you will learn how to organize a home shop, what equipment is needed and what kind of materials used in production. Also you will get acquainted with the technological tricks that will make your home better than the factory unit.

Content

• What you need to organize a home workshop:
• Equipment and Supplies
• shape
• expendable material
• About plasticizer
• Production technology:
• Area and shape
• batch
• laying
• Demoulding and storage
• The benefits of home shops: Economy at a Glance

How to save on building materials and reduce the cost of production? What's more profitable to buy stuff or make it yourself? These issues are always relevant, especially in times of crisis. But if an independent production of glass, metal sheets or drywall are not talking, then building block or expanded clay bricks can successfully produce their own hands on the plot or at the cottage.

Independent production will save up to 30% of funds spent on the purchase of the unit, and to control the quality of products.

Many would argue that the cottage industry can not compete with the quality of the factory, but this belief is debatable. Now on the market there are many shops that will present their products as appropriate building codes and have a valid mark.

If you take one sample from ten different manufacturers and give them to study in the construction lab, six of them will show a result below 30 mark, which is the maximum for the minimum figure building block.

To reduce the cost of products, some manufacturers go to austerity measures, which often have a criminal nature. Many businesses violate the production technology for the sake of profit, which makes them dangerous product. For this reason, small construction volume is recommended to organize a home workshop.

The advantage of home-made:

• It saves up to 30% of the funds;
• It does not require expensive equipment;
• It requires no special skills;
• you can not hire staff;
• work in a free schedule;
• It brings extra income.

What you need to organize a home workshop

To organize the production it is necessary to comply with three mandatory conditions.

• Smooth concreted surface area of ​​20 m², covered with a canopy or tent.
• Concrete (normal pear).
• Deep vibrators Small size.

Equipment and Supplies

Do not think that all this expensive equipment. In the secondary market, all sold at low prices. For example, a used concrete mixer volume of 180 liters can be found for 5000 rubles. New vibrator can be purchased at a cost of 2,000 to 5,000 rubles. Concrete pad can also be manufactured in-house, at a cost of 7000-10000 rubles.

Also need auxiliary tools: spades, shovels, trowel, bucket, plastic container, hacksaw, hammer, set of keys and screwdrivers, garden cart. Another item of expenditure will be cellophane film, which is required when the drying of finished products. Most of the following equipment is available in almost every home and the purchase of these things you can not make to the overall estimate.

shape

For the production of the block need shape and may be made of plywood, metal, wood. The block size is 200h200h400 mm. Optimal and inexpensive cost will be shuttering of boards. For this fit with the board 200 mm wall height and at least 25 mm thick. Boards should permeate the hot waste oil. This will give them protection against moisture and prolong life. From the prepared boards must twist cells with screws, which on the internal volume should match the size of the block. The best option wooden formwork - a longitudinal section of the 4 cells.

Plywood formwork - This option is more expensive, but water-resistant plywood has its advantages. If you make the form of plywood, the geometry of the product will be flat and smooth surface. With the use of plywood forms can make a color block lining. Such a unit is suitable for building a house, garage, baths, fence, utility structures. Its advantage is that the color blocks look presentable and does not require additional cladding.

Metal forms the most expensive but also the most practical. They are characterized by long service life and increased functionality. Metal casing can be disassembled, which significantly speed up the production process and facilitate their transportation and storage. The metal molds are not damped vibration, allowing the mixture to bring better and faster air.

expendable material

As the consumables necessary: ​​cement 400 grade M or 500 M, building sand, filler, plasticizer C3. With the purchase of plasticizer is no problem. Implement it in the field of cement sales, or where the sold material for manufacturing of paving slab. We should also consider a filler, or as it is possible to name: the main component of the unit.

In different regions there are different kinds of fillers used in the production of concrete products. In regions where there is clay, expanded clay common. In those places where a lot of coal is used in large quantities there is a slag. Also, throughout the country, you can easily buy broken or dropouts. In some cases, for the production of concrete products used battle brick and concrete baby.

Should select a filler for the intended use of bricks. If the goal is to make the building a warm, the perfect slag. But this unit is suitable only for single-storey buildings with a light roof, since the slag material is lightweight, has the air pores and can not carry a heavy load. If selected as a filler concrete block, you should buy only for construction purposes, small fraction expanded clay. He is able to carry the load, and from it we can construct buildings up to three floors.

In cases when the building is the altitude of up to five floors and is equipped with concrete floors, you must make a block with rubble. For this purpose, suitable gravel fractions 5-10, or 10-20 mm. This product will be much heavier than a block of expanded clay or slag, but it is necessary to take into account that it will affect a large load.

About plasticizer

Plasticizer - is one of the best inventions that allowed to produce high quality concrete at home. With the use of this additive could avoid steaming concrete. Also with the use of a plasticizer can eliminate pressing, since the movable air mixture is removed much more effectively.

Advantages of a plasticizer:

• increasing the mobility of concrete solution;
• reducing the amount of water in the solution;
• decrease in porosity of the concrete;
• reducing the term of the product forming three times;
• fast curing;
• ready-mixed concrete reinforcement characteristics (cold resistance, strength, water resistance);
• ease of application in a mixture form.

plasticizer Cost - 50 rubles per kilogram, but its share in one product is minimal. The plasticizer is dissolved in mixing water at a ratio of 1: 100. That is, in 100 liters of water is required to fill only 1 kg of dry powder. If you do recalculated per unit ready, then the plasticizer cost is 30 cents per item.

Production technology

Any production to start with the purchase of material. Prerequisites - is cement, sand, a plasticizer, a filler. All this should be ordered, delivered to your site and placed in close proximity to the production site. Cement and plasticizer should be stored in a dry place. For this fit the garage or shed. Bulk materials must be closed against precipitation thick film.

Step 1. Area and shape

First of all you need to prepare the work area. To do this, bring electricity to the mixer, to prepare extender vibrator. Also, you need to prepare the mixing water in the required quantity. For one working day will be sufficient to 200 liters of water diluted with a plasticizer.

You should also collect the shuttering wall and apply waste oil. This is necessary in order to avoid sticking to the walls of the cement mixture. Formwork should be positioned in such a way on the tarmac, that between them it was convenient to take. The necessary equipment must be on hand.

Step 2. batch

Mixing is done as follows. First, the mixer is placed cement, sand and filler. The mixing ratio should be such: 1 part of cement, 2 parts of building sand, 4 parts of filler (expanded clay, gravel, or slag). All the components necessary to fill in the mixer and dry mix for five minutes.

After the mixture was stirred, enter the mixing water. The amount of water should be determined by eye, but one should know the proportion. The water is calculated by the number of cement used. To calculate it there is a special factor which is determined by the volume of water. To manufacture the concrete block by vibration casting rate is 0.4. That is, if one batch with proportion of 1: 6 out of 50 kg of cement, the cement weight multiplied by 0.4, and the number of turns required in water liters. 50h0.4 = 20 liters of mixing water. Water is necessary to introduce small portions until the desired concentration. The mixture should be stirred for 15-20 minutes.

It will be appreciated especially humidity in each region. If the filler is wet, it is necessary to reduce the amount of water, and if dry, then increase. The solution should resemble thick cream, and do not spread. You should know that a high amount of moisture in the concrete solution spoils. The excess water leaves the pores of the concrete, making it brittle.

Step 3. laying

When the mixture is ready, it is necessary to begin to fill. The finished mixture should be using a bucket and trowel lay in shape. Of kneading is necessary to leave a bucket of solution, which will be spent on refilling in shape after work vibrator.

When the mixture is expanded in shape, it should begin its stacking. This is done using vibrators. The working part of the vibrator is placed into a mold filled with the mixture. When laying a mixture need to go through all the corners of the form. This is necessary in order to avoid air voids. When shrinkage mixture which gives vibration should be reported to the solution to the desired level. To obtain the same block size, the form must be filled to the top.

After the molding is produced, it is necessary to cover forms cellophane film. This is no less important stage in the manufacture of concrete products than the actual filling or preparing components. Concrete must be mature and not dry. Do not allow anti-aging products on the open sun under the influence of wind. Concrete in the process of aging produces heat, which must be preserved. Under the film will take concrete procedure resembles steaming. In this state, the brick should be daily.

Step 4. Demoulding and storage

After one day the unit can extract form. If used plywood or wooden forms, they should be carefully disassembled. It will not allow the product to chip the edges. It is not necessary to shake the product form. In the application of metal molds can be retrieved articles by pressure from above. If the metal mold with the correct geometry, the product will come out easily.

Ready brick is necessary to lay down in rows on a tray and cover with foil again. As one of the best storage options - is the use of stretch film, which is wrapped brick on a pallet. It not only saves valuable moisture but will not let fall the contents during transport. Use a block to the construction can have on the fifth day after manufacture.

The benefits of a home workshop

Such measures reflect only the economic benefits and it is not difficult to find. It is possible to make a very simple way. Average unit weight - 20 kg. If the entire transfer material used in tons, then it happens that the conditioned production cycle took 1 ton of cement, 2 tons of sand, filler 4 tons. Plasticizer on the number of products it will take 6 kg, which will be released in the amount of 300 rubles. An example is given building block of rubble.

Cost of consumables:

• 1 ton of cement - 5000 rubles.
• 2 tons of sand - 800 rubles.
• 4 tons of rubble - 2400 rub.
• 6 kg of plasticizer. - 300 rubles.

The total amount of costs - 8,500 rubles.

Of this amount obtained 6 tons of finished products or 300 blocks. The amount of costs 8500 should be divided into 300 blocks, giving the raw material cost per unit of product. Thus, the unit raw material cost was 28.3 rubles. 1.7 ruble should lay on energy costs.

Savings in numbers

The average retail price of this unit is 40 rubles. Savings from domestic production is obvious and, if necessary, build a house, which will take 8000 blocks can be saved 80,000 rubles. But the house always need a garage, sauna, outbuildings and purchased equipment will not stand idle. We can conclude that the brick with his own hands - it is advantageous that in addition to the benefit of their own economy will make a profit from the sales.

It should also be borne in mind that in order to save, you can adjust the quality of the products and avoid costly overruns material. For example, in the two-storey house requires 10,000 building blocks. Ground will bear large load, and it is better to put the block made of high-grade constructional expanded clay (clay gravel) or rubble. The best option would be for the second floor of block cheaper heat expanded clay (expanded clay crushed stone).

The best option for partitions and internal walls will be rubble. Such walls have high sound insulation and well hold the anchor for hanging furniture, appliances, electronics. Combined use of different types of filler material for the construction of a single facility will improve the quality of construction and savings of up to 30,000 rubles for every 10,000 units.

On the topic you can read about the makeshift Lego-brick. In Mexico also invented bricks puzzle. A faster and more profitable to build from homemade-blocks TISE. In the video - a brick building in a colonial style.

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