As 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 alter and improve the structural performance of concrete blocks and make them suitable for use in a wide variety of designs. Therefore, the topic of production of foam and aerated concrete is relevant.
First of all, concrete blocks are required to have high thermal insulation and soundproofing. Sometimes the production of such concrete blocks is successfully combined with other industries and waste from them is used - for example, expanded clay, expanded polystyrene, 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, by reducing the 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 - is actually quite difficult. Therefore, in the construction industry, special foam or gas is used to produce cellular concrete.
Hence the name of two currently very popular materials: aerated concrete and foam concrete .
How is aerated concrete and foam concrete produced?
Aerated concrete is produced by introducing special substances into the cement mortar that cause the gas formation process, or simply emit gas during a certain chemical reaction. The main component in this case is aluminum powder, which reacts with products released during cement hydration. From the point of view of chemistry, hydrogen is released, causing the formation of pores in the cement mortar. Visually, it looks like a dough after yeast has been added to it. Cement mass begins to increase in volume and after it hardens, porous concrete is obtained.
Foam concrete is produced by mixing cement mortar with a special foam prepared in advance. In this case, the bubbles of foam, which contain air, are evenly distributed throughout the volume of the mixture. The effect of porosity, as in the previous material, persists after solidification.
Typically, both types of concrete blocks are used for construction: load-bearing walls are made of more durable aerated concrete blocks. They carry the main structural load. Foam concrete blocks, which are 20-25% cheaper, are used for non-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
Consider the investment required to open a 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 at 105600-283800 rubles. (capacity 10 cubic meters - 30 cubic meters per shift). For the production of aerated concrete - 29800-85000 rubles. (capacity 12 cubic meters - 50 cubic meters per shift).
In addition, a foam generator (27, 800 rubles) and a compressor (37, 800 rubles) and a peristaltic pump (57, 700 rubles) will be required for the foam concrete mini-factory.
Forms 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 pcs are required).
Total: minimum investments 538, 700 rubles., Maximum - 1, 332, 100 rubles.
- 1 cc m of foam blocks costs about 3, 000 rubles.
- 1 cc m gas units costs about 3600 rubles.
Consumables (per 1 cubic meter):
- Foam concentrate 75 rub. for 1 kg (for foam concrete)
- Aluminum powder 500 g, 105 rubles. per 1 kg (for aerated concrete)
- Sand 300 kg - 350 rubles. per cubic meter (1.3 t)
- Cement - 100 kg (2 bags of 189 rubles.)
As you can see, material costs are negligible: about 540 rubles. for 1 cube m of foam concrete or 520 - for aerated concrete.
How much can you earn on the production of concrete blocks?
Gross profit from 1 cubic 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, minus wages for workers, utility bills (the production of concrete blocks is quite water- and electro-waste), will be at least 30-35% (about 200-220 thousand rubles) per month.
It turns out that when half of the net profit is paid back, for example, equipment for the production of concrete blocks purchased by installments, it will pay off in six months, and with the purchase of the most powerful equipment, the payback will be even faster - about 3-4 months.
This will come at the expense of more production. In general, it is more advisable to purchase the most powerful equipment: with a price difference of 2.5 times the lowest power, 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 are much more expensive than ordinary ones.
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Footage on the production of aerated concrete and foam concrete