Equipment for cinder blocks at home. Do-it-yourself technology for the manufacture of building concrete blocks. Business development and expansion
A cinder block is a building material made from a special concrete mixture by vibrocompression. Buildings made of this material are warm, the construction process is quite simple and does not take much time. Thanks to this, cinder blocks have become very popular in private construction.
In addition, you can build a very profitable business on cinder blocks. To do this, you must have a special recipe and production technology, as well as try to automate the process of making cinder blocks with your own hands at home.
Cinder blocks can be both hollow and full-bodied. Solid cinder blocks are most often used for exterior cladding and foundations, as they have excellent strength characteristics. In turn, hollow cinder blocks are able to provide good sound and heat insulation of walls. In addition, due to voids, it is possible to significantly reduce the consumption of raw materials, which will affect the cost of production. Strength characteristics at the same time fully satisfy all requirements.
Hollow blocks in which slag (cinder blocks), expanded clay (expanded concrete blocks) or sawdust (arbolite blocks) is used as a filler. Such blocks have very good heat-insulating properties, which allows them to be used as a heater. Using the heat-insulating blocks described above in construction, it is possible to make the walls of the building warmer without increasing their thickness. These blocks are much larger than ordinary bricks, making construction work much faster and easier, and mortar is saved during laying.
When using fillers, which are most often free of charge, it is possible to significantly reduce the thermal conductivity and cost of products, as well as increase their strength characteristics.
Advantages and disadvantages
To the benefits This building material includes the following:
- It is possible to make cinder blocks with your own hands at home.
- There are various methods. The material, in addition to autoclaving, can be dried by steam treatment or at room temperature.
- The building will have minimal heat loss.
- Short construction time and low cost. The walls are built very quickly due to the large size of the blocks. In addition, the consumption of mortar during construction is quite small, which saves time on its preparation.
- By changing the proportions of the recipe in the manufacture of cinder blocks, it is possible to endow products with certain properties that are necessary for their use.
- You can produce products of any shape and size, which is very convenient. In addition, this can often greatly facilitate installation.
But cinder blocks, like any other material, have some disadvantages:
- The issue of ecology is quite acute, especially for products containing blast-furnace slag.
- Relatively low frost resistance.
- The material requires enhanced protection against moisture.
- Cinder blocks are quite fragile and therefore not suitable for foundation installation. Even when erecting walls, it is necessary to take into account the load and height of the future building.
Application
Most often, cinder blocks are used for the construction of low-rise buildings, but according to some reports, cinder blocks can also be used for building foundations if they contain cement of a “high” grade.
Cinder blocks can act as an additional insulation during the construction of frame structures.
General requirements
High-quality cinder blocks can even be made in a garage, provided that you know the recipe and manufacturing technology. A standard cinder block has dimensions of 39x19x20 cm and three small holes.
In order for the cinder block to be of high quality and have the necessary strength, you will need:
- vibropressing equipment;
- high-quality cement (not lower than M400);
- blast furnace slag;
- coarse sand.
Slag is obtained during the processing of coal, that is, it is the best filler for blocks. But at present, due to the active use of gas, ash and slag have been produced in much smaller volumes. Therefore, more and more often, slag is replaced with zitoconcrete, which has a higher cost.
This building material is now becoming more and more popular due to its low price and excellent sound and heat insulation. In addition, calculations show that when making cinder blocks with your own hands for one block, you will need 0.011 cubic meters of mortar (if you use a ratio of 1: 7), that is, a bag of cement is enough for you to produce 36 blocks! This is just a great result.
High-quality cinder blocks must have the most accurate geometry possible, since if there are various flaws and large irregularities on the surface of the blocks, you will have to spend a significant amount of money on the construction of the walls of your building. In order to get a perfectly even cinder block, you must always fill the vibroform to the very edges, otherwise the blocks will be crooked. It is desirable to fill the vibroform not even to the brim, but with a margin, since then the concrete will be slightly shaken by vibration.
The production process is as follows: first, the vibroform is turned on for 5-15 seconds, after which it is necessary to evaluate the level of the solution in the form. In the event that it is below the edge of the form, you will need to set the clamp and turn on the vibration again. You need to turn off the vibration at the moment it hits the limiter. After that, you will need to simultaneously pull out the mold and turn off the vibrator.
How to fill out the form?
If you want to arrange an independent production of cinder blocks, you must remember that the ideal composition simply does not exist, since each master has his own unique recipe, depending on the slag and suitable for specific needs. But there is a certain standard according to which cinder blocks have the following composition: 1.5-3 parts of water, 1.5 parts of cement, the grade of which should not be lower than M400, 2 parts of sand and 7 parts of slag. As mentioned above, a standard cinder block has dimensions of 39x19x20 cm, while in private construction dimensions of 40x20x20 cm can be used.
In addition to slag, other coal combustion wastes, as well as brick scrap, gypsum, screenings of granite and stone, perlite, processed sawdust, gravel and ash can be used as a filler for blocks. In order to achieve greater plasticity, you can add 5 grams of plasticizer to each block during vibrocasting. The plasticizer is able to significantly increase the strength of the block, save it from cracks, as well as increase its water resistance and frost resistance.
Be very careful about the amount of water, make sure that the blocks do not spread when removed. For greater certainty, you can test the solution - if it connects in a fist, and crumbles when it falls, then this is exactly what you need!
The concrete that is required for the construction of a small private bath can be prepared by hand, and if you started building a larger facility, then you will need an electric concrete mixer with a volume of about 0.2-0.5 cubic meters.
Manufacturing process
To get high-quality cinder blocks as a result, you need to follow these steps:
- At the very beginning, it is necessary to put a solution with a slide into the mold and turn on the vibrator for 3-5 seconds to precipitate the solution. If the solution is not enough, then it should be reported. After that, you need to insert the clamp and start the vibrator again. When the pressure reaches the limiter, the block formation will be completed.
- Next, you need to carefully remove the form, including the machine.
- Finished blocks need to be dried for about 5-7 days, and they will reach full hardening, being warm and at high humidity, only after a month.
- You can carefully transfer the blocks without fear that they will break in a day, but you can store them together only after a week. If, when creating blocks, you added a plasticizer, then it will be possible to transfer and store them in 6-8 hours.
Most often, finished cinder blocks are stored in pyramidal piles, each of which can contain about a hundred blocks with small gaps between each other for good drying. After a couple of months of drying, these blocks become suitable for construction.
Production of a vibrating machine
Making a cinder block machine
If your goal is to build one small building, for example, a bathhouse, then you can produce blocks in ordinary carrying boxes. If you are going to build a larger object, then you will most likely need a machine that may not have a vibrating plate and be homemade. Moreover, the production of blocks can drag you out and you may want to open your own business, which will require you to automate the process. In addition, after the construction of the bath, you can build a good shed, a beautiful gazebo or even a garage. If you have a vibrating machine made with your own hands, you can save a lot of time with it.
In order to make a machine for the production of cinder blocks with your own hands, you will need:
- fittings having a diameter of 12 mm;
- sheet iron having a thickness of about 3 mm;
- grinder and electric welding;
- a high-speed engine with a power of approximately 0.5-0.7 kW, which must necessarily have two shafts.
When making cinder blocks with your own hands, the vibration time is only 5-15 seconds. Then the vibroform is removed and after a day the cinder blocks can be stored. Using a simple home machine, you can make about 50 cinder blocks per hour, which is a pretty good result.
Among the many concrete products on the market, cinder blocks stand out. They quickly gained popularity among private developers, thanks to a set of advantages. The increased dimensions and low weight of the products greatly facilitate the laying of walls. By making cinder blocks on your own, you can significantly reduce costs. A cinder block production machine designed for domestic use can be made on your own.
Cinder blocks - characteristics and purpose of the material
One of the reasons for the increased popularity of slag-filled concrete blocks is the low cost of the material. It is associated with the use in the production process of waste from metallurgical enterprises - slag.
Along with traditional components, Portland cement and river sand, various aggregates are used:
- brick fight;
- crushed stone screening;
- granite chips;
- various slags and ashes;
- expanded clay particles.
The manufacturing process is carried out in various ways:
- industrial method at specialized enterprises with the processing of products in drying chambers;
- at home from available raw materials, using a self-assembled machine for making blocks.
On home-made equipment, you can produce various types of cinder-concrete products:
- full-bodied, with an increased margin of safety. They are used quite rarely, as they retain heat worse;
- hollow, characterized by high thermal insulation properties. To ensure strength, the volume of cavities should not exceed 1/3 of the total volume of the product.
Dimensions of products are determined by the size of the form. With independent production of products, the size of the molding box can be any. However, many prefer the standard dimensions of 19x18.8x39 cm.
The increased volume of the cinder block can significantly reduce the duration of various types of construction work:
- erection of capital walls;
- construction of internal partitions.
It is perfect for the construction of utility buildings, sheds, storage facilities. If you need to make a cinder block yourself, the machine allows you to quickly solve the problem. The resulting material has many advantages:
- high thermal insulation characteristics. Due to the reduced thermal conductivity, the material prevents heat loss;
- increased dimensions and low weight. This makes it easy to transport products and quickly build walls from them;
- resistance to the development of microorganisms. This is achieved due to the properties of the slag included in the structure of the block;
- low price. Do-it-yourself cinder block machine allows you to make products that are cheaper than purchased blocks.
The advantages also include the fact that slag-filled blocks can be easily machined, effectively absorb various noises, and are not afraid of high temperatures.
The material also has weaknesses:
- low durability. The period of operation of cinder-block buildings is up to three decades;
- reduced margin of safety. The characteristics of the material allow the construction of buildings with a height of no more than two floors;
- the appearance of cracks under the influence of shear forces. During shrinkage, cracking occurs along the cinder block array.
To ensure an attractive appearance of buildings, the cinder block surface needs an external cladding. These shortcomings do not stop developers who wish to build an outbuilding or a small building in a limited time at low cost.
You can use homemade cinder blocks a month after they are made. Choosing which machine to use for the manufacture of cinder blocks
After deciding on the manufacture of block products on their own, the problem arises of choosing a unit for their production. Many decide to make their own machine for the production of cinder blocks.
When deciding on a device, it is worth considering the following design options:
- a simplified device that provides the ability to manufacture block products at home;
- an improved unit, the design of which provides for a mechanism for tamping and extracting finished products.
The choice of the optimal option is carried out depending on the need and availability of funds.
Simplified cinder block machine with your own hands - drawings and recommendations
With a small need for material, there is no need to manufacture a complex unit equipped with a vibration motor and special mechanisms. A simplified method allows the production of products in special molding boxes.
The technology provides for the following works:
- Assembling molds and oiling the surface inside the box.
- Pouring into collapsible containers of cinder block mortar.
- Exposure for 5-6 hours until the composition sets.
- Disassembly of the box and careful extraction.
- Drying of manufactured products under a canopy or indoors.
To build this kind of machine, you should have the skills to work with a welding machine and a plumbing tool The use of wooden or metal inserts, as well as glass containers, allows the production of hollow blocks. It is not difficult to make a simplified machine for cinder blocks with your own hands - it is a metal or wooden container, the size and shape of which correspond to the parameters of the product.
An improved machine for the production of cinder blocks with your own hands - drawings and device
For the manufacture of the upgraded unit, drawings will be required. You can study the existing machine for self-development of sketches. Before starting design work, it is important to make sure that the device is working. It is advisable to manufacture complex equipment with an increased need for cinder blocks. In any case, when planning to assemble a professional cinder block machine with your own hands, you need to develop the drawings yourself or purchase ready-made ones.
In such a machine there are special mechanisms:
- ramming device. Compaction is carried out by a vibration motor. It is an engine with a power of up to 1.2 kW with a load placed eccentrically on the shaft. You can use a purchased vibration motor. As a result of vibration action, air pores are removed, and the material is evenly distributed over the mold box. The result of ramming is an increase in density and strength properties;
- lifting mechanism. It facilitates the removal of cinder blocks from mold boxes. From a variety of designs, you can always choose the right option. The simplest solution is a U-shaped handle welded to the side surfaces of the container. By lifting the molding box by the handles, you can remove the hardened cinder block.
The size of the mold must correspond to the dimensions of the cinder block, exceeding its height by 50 mm. This will allow you to load an increased volume of the mixture, which, after compaction, will acquire the required dimensions.
To make a cinder block with your own hands, small-sized vibrating machines are used, which are capable of producing small batches of this material. We assemble a machine for the manufacture of cinder blocks with our own hands
If you want to make a homemade cinder block machine with your own hands, you need to draw or purchase ready-made sketches, as well as take care of the materials and tools necessary to complete the work.
Getting ready to assemble a machine for cinder blocks - preparation of materials and tools
The arsenal of home craftsmen usually has the required equipment and tools. Catalog of the necessary equipment and materials:
- electric welding device;
- grinder with a disk for cutting metal;
- a set of locksmith tools;
- vise;
- sheets of three-millimeter metal;
- cutting steel pipes;
- electric motor or ready-made vibrator;
- bolts, washers, nuts for fastening parts.
The amount of metal for the manufacture of the device is determined in accordance with the drawing or sketch, which shows all dimensions.
First of all, workpieces are cut from a sheet of metal 3 mm, work with a grinder should be done carefully How to make a mold for a block machine with your own hands - drawings and assembly
In order to make a home-made machine for a cinder block with your own hands, drawings and diagrams will be required both for the molding box and for the unit itself. Let's start with the mold.
Make it according to the following algorithm:
- Mark the contours of the parts on a metal sheet, cut the blanks to make a molding box.
- Weld the shell of the future container, check the observance of right angles.
- Cut off pieces of pipes with a grinder, the length of which corresponds to the height of the cinder block.
- Make cuts along the axis from opposite sides of the pipes, give the blanks a conical configuration.
- Weld them to the base of the box, connect them with a transverse jumper to increase rigidity.
- Weld the base with conical inserts to the shell, fix the plugs on the end of the pipes.
- Make two handles for moving the mold box, fix them on both sides of the structure.
- Make the cover of the molding box, make holes in it that correspond to the dimensions of the technological inserts.
- Fasten the stops inside the box at a level corresponding to the height of the block. They act as a stopper for the lid.
The use of a group molding box with increased dimensions will increase the productivity of the equipment, and the use of a collapsible casting mold will facilitate extraction.
Do-it-yourself drawing for making a machine How to make a block making machine yourself
As a material for manufacturing, use the metal profile available in the household.
Sequencing:
- Weld the sidewalls of the bed, connect them with jumpers.
- Prepare a work platform and secure between the uprights.
- Attach the vibration motor mounting studs to the platform.
- Fix the eccentric balancer on the motor drive shaft.
- Prime the surface of the metal, then cover with paint.
- Connect the power cable to the motor and carry out a test run.
Having carefully studied the previously developed project and drawings, it is not difficult to make a machine for making cinder blocks with your own hands.
How to prepare a solution for a machine for the manufacture of cinder blocks
It is important to properly prepare the solution so that the cinder block made at home has the required properties. Necessary materials:
- coal ash or metallurgical slag;
- sifted sand;
- fine-grained gravel or screenings;
- cement M400 or M500.
The name itself speaks for itself what this block is made of, and it is made from coal slag, which remains after the boilers are fired in a coal-fired boiler house It is allowed to introduce additives that reduce the duration of hardening and increase strength. The ratios of the ingredients affect the characteristics of the finished material.
Use the following recipes:
- mix ash with cement in a ratio of 7: 2, add water to a plastic consistency;
- mix ash and screenings in equal proportions, add 10–12% of cement from the total volume, dilute with water.
When mixing, be guided by proven recipes.
We check the machine for the production of blocks - we stamp cinder blocks with our own hands
Consider how to use the machine for the manufacture of cinder concrete products:
- Install the unit on a solid base, connect the voltage.
- Prepare the cinder block mixture according to the manufacturing technology.
- Fill the mold box with mortar and turn on the vibration motor for one minute.
- Add solution up to the upper mark.
- Install the cover, turn on the vibration motor.
- Tamp until it touches the cover with thrust elements.
- Carefully remove the forming container.
When the fresh block has set, remove it from the box. Dry the building material in a dry and closed area.
What to look for when making a cinder block machine
When building a house, a bathhouse or an outbuilding, you can save a lot by using a machine designed for the manufacture of cinder blocks. It is not always necessary to purchase a machine made in the factory. It is not difficult to make a machine for making blocks yourself. Pay attention to the use of proven drawings, as well as study the recipe and understand the technology.
-> Production, construction, agriculture
Mini-production of cinder blocks at home
Everyone knows about the advantages of using cinder blocks in construction today. Why is cinder block so good? The main advantage is, of course, its low cost. Among other advantages, good structural and thermal insulation properties can be noted. In a word, cinder block is an excellent building material that is in constant demand in the building materials market.
And yet, now the most important thing for us is the low price of cinder block production and the extremely simple technology for its production. To open your own small production of cinder blocks No complicated fixtures or tools are required. All you need is to make suitable molds for casting cinder blocks. Moreover, you can make cinder blocks not only of standard sizes, but also make cinder blocks for your specific needs - wide, narrow, long, short, absolutely any size!
The main components of cinder blocks are cement, water and various fillers (slag, sand, crushed stone, crushed brick, expanded clay and even sawdust). The cost of manufacturing a cinder block is very low due to the use of fillers, and the most expensive component of the cinder block is, of course, cement. The filler, as a rule, is purchased literally for a penny, or construction waste (for example, broken brick) is generally used and what is available, as they say, is “at hand”.
How to open your own mini cinder block production
So, what is required to make cinder blocks with your own hands? For a mini-production of a small number of cinder blocks oriented primarily for personal needs, you only need a suitable container for mixing the solution and molds for casting cinder blocks of the required size. The number of molds for casting cinder blocks directly depends on the volume of your production. Calculate how many cinder blocks you will make per day, if 20, then 20 forms will be required, if 100, then, respectively, 100. This is due to the fact that the finished cinder blocks will be dried directly in the forms.
Forms for cinder blocks usually wooden or metal, in the form of an open box from the bottom and side walls. To save wood or metal, you can make a mold with several compartments, so from 4 to 6 blocks will be poured into one mold at once. When made in this way, the solution must be made thinner so that the mass is more homogeneous and fills the molds well. The size of a standard cinder block is 400 x 200 x 200 mm, but you can make them any to your specific dimensions.
To save the solution and reduce the weight of the cinder block, punches- blanks (as a rule, they have a cylindrical shape), filling a part of the internal volume of the cinder block, which are removed after the block has dried. Even empty glass bottles can be used as punches for home mini-production of cinder blocks - we insert them upside down, remove the excess solution and level the surface. After 6 - 8 hours, the punches are pulled out, and cavities remain in the block. The number of punches can be from 2 to 3, it all depends on the size of the cinder block.
Cinder blocks are dried for about a day right in the form, then they should be carefully pulled out and stored in piles. The time for the full curing of the cinder block is about 28 days.
The described technology is perfect for the organization mini-production of cinder blocks the so-called "artisanal way" at home.
For a more serious production of cinder blocks, it will be necessary to purchase or manufacture some starting equipment. The basic set includes a concrete mixer and a vibrating table. These two simple things will allow you to greatly increase productivity.
vibrating table allows you to significantly reduce the production time of the cinder block and reduce the number of molds used for pouring. The molds themselves are best made from metal. For convenience, weld handles to it, and to the bottom 2 - 3 pipes with a diameter of 50 - 80 mm - to create internal cavities.
The use of a vibrating table allows you to pour a thicker solution. After laying the solution, the form is sent to the vibrating table, where the block is compacted for 30-40 minutes. Next, the form is turned over and the cinder block is removed with a light tap (it should not fall apart, we achieve the desired density empirically). Remember, it can not be disturbed for about a day until it has completely hardened. Therefore, it is necessary to provide in advance a flat, clean area for storage and final drying.
Vibrating table can do it yourself. This will require a sheet of metal approximately 800x800x5 mm, an electric motor (2-3 kW) and springs. We weld 4 springs to the sheet in the corners, and in the center we fix the electric motor, we put on a pulley with a displaced center on the shaft. Install on a solid base and secure. Remember, the power cable must be securely connected and insulated! The metal sheet of the table should be securely grounded.
Solution for the production of cinder blocks.
Cement can be used any grade from 200 to 600.
Examples of mixtures for cinder blocks based on cement ПЦМ-400
(weight in kg, water in liters).
Heavy and dense cinder block:
1. Cement 240, sand 1950, water 90 - 130.
2. Cement 200, sand 920, crushed stone 980, water 90 - 130.
3. Cement 230, broken brick (fraction 5 - 20 mm) 990, sand 540, water 90 - 130.
Lighter and slightly less durable:
1. Cement 250, expanded clay 720, water 100 - 140.
2. Cement 200, ash (coal or oil shale slag) 960, water 90 - 130.
3. Cement 260, sawdust (wood) 150, sand 1100, water 100 - 140.
You can combine different materials. The recommended ratio of cement is 1 to 8 or 1 to 9, but if you want to increase the strength of the block, add a little more cement. But even with such a content of cement cinder blocks become very durable.
And don't forget that cement takes 28 days to reach its final strength!
Equipment for the production of blocks at home
The desire to reduce the cost of construction involves the use of a variety of tools and materials, many of which are worth making on their own. The use of cinder blocks is one of such methods. Although this building material belongs to the "old-timers" of the construction market, the demand for such products in individual construction is comparable to the popularity of foam blocks and gas blocks that have appeared relatively recently. This is due to the fact that equipment for the production of cinder blocks at home does not require significant financial costs. The quality of building materials made at home using a machine is not inferior to factory products.
Cinder block is one of the most popular materials from which buildings of any type are built.
Cinder blocks: composition and proportions
The cheapness of cinder blocks is due to the use of a wide range of materials as a filler, many of which are waste from various industries. Accordingly, there are several recipes for mixing the solution, but cement remains the main component. Builders prefer to use Portland cement M400. In the presence of cement of other grades, the proportions will be somewhat different: grades with a smaller number will require an increase in the cement content by 15-20%, the use of higher quality cements can reduce its content. In addition to cement, the solution for cinder blocks includes a filler and a plasticizer. The filler can be improvised materials available:
- sawdust;
- screenings;
- ash;
- construction waste, including brick fight;
- sand;
- small stones, gravel.
Plasticizer - additive is not required, but it improves certain properties of the solution. There are plasticizers that increase the moisture and frost resistance of the mixture, which is important for areas with a harsh climate. You can find additives that improve the strength characteristics of the solution, prevent the formation of cracks, and accelerate the process of hardening of the working solution. The percentage of plasticizers in the mixture is insignificant: 3-5 grams of the additive is enough to manufacture a unit of production.
The very technology of production and the composition of cinder blocks provide that the blocks use special devices and machines that you can do yourself
The name "slag blocks" was assigned to this building material, since in its manufacture in Soviet times, mainly coal slag was used - waste from metallurgical production. Today, another material can also act as a filler, but as an example, we will give the proportions of the slag mixture:
- three parts of slag;
- one part of plaster;
- water.
The slag mixture is moistened before use. The preparation of such a solution takes 5-10 minutes, while one cubic meter of the finished mixture will require approximately 340-360 liters of water. The addition of plasticizers improves certain characteristics of the mixture, increasing the cost of the cinder block. When using dyes, it is possible to obtain products with different colors that improve the aesthetic perception of the building.
Hollow blocks reduce the cost of construction, while improving the sound and heat insulation properties of products, but the strength of such blocks does not allow them to be used for the production of foundations and walls subject to high loads.
Production of cinder blocks at home
Ready-made equipment for the manufacture of building blocks is quite expensive. The purchase of factory vibrating machines is justified only when conducting construction work carried out in large volumes. In private construction, it is preferable to rent such equipment, but the option of self-production cannot be ignored.
It is the cinder block that is the most profitable material for construction on its site, because in this case the process is fast, economical and reliable.
Cinder blocks in molds
An alternative option is the production of building blocks without the use of vibration equipment. This will require forms of the required geometry and dimensions. They are rectangular boxes with side walls and a bottom. It is preferable to make molds consisting of two or three blocks - this will save material.
The solution poured into the mold is made plastic, which will prevent the formation of voids. In the manufacture of hollow blocks, any suitable material is used as a void former, for example, glass bottles. After filling the form with a solution, it is rammed and left for a day or two. The removed block must stand for a month, after which it can be used for masonry work.
Vibrating machines for the production of cinder blocks
The quality of products made without the use of vibration equipment leaves much to be desired, because the density of the mixture during production will be much lower. Therefore, if this criterion is among the determining ones, it is better to invest in a machine with a vibration unit. They are of two types:
- stationary;
- mobile (popularly referred to as "layers").
Making a cinder block at home is possible using both wooden and metal molds.
Cinder block has established itself as one of the most convenient and inexpensive materials for the construction of small buildings of 2-3 floors. It is quite easy to install, weighs little, retains heat well and saves a lot of time, not to mention money. The last point plays a decisive role, especially when you consider that cinder blocks can be made independently at home. Then the savings on construction turns out to be very significant, which cannot but please the zealous owners. In this article, we will tell you how to make molds for cinder blocks with your own hands in order to get high-quality building material.
Cinder block is the result of pressing concrete with various impurities using vibration equipment. Building with this material is a real pleasure because it is light, large and has clear edges that provide a snug fit. You can build a box house from cinder blocks in just a couple of days, while using bricks will take much more time and effort.
Cinder blocks are hollow and full-bodied. Hollow ones have special holes where heat-insulating material is then laid. Thus, the block becomes lighter and better protects from the cold. They are made from cement, foundry waste and various fillers, as a result of which the material acquires good heat and sound insulation qualities.
Many economical or just hardworking owners prefer to make cinder blocks with their own hands. This allows not only to reduce construction costs, but also to control the strength and performance properties of the blocks by adding various ingredients to the solution.
General requirements
You can make cinder blocks anywhere - even in your own garage. The main thing is to strictly adhere to the technology and find your ideal solution recipe. A standard hollow cinder block has dimensions of 39x19x188 mm and three holes in the center.
In order for the material to turn out to be of high quality, strong and durable, it is necessary to take coarse sand, blast-furnace slag, cement of a grade not lower than M400 for the mortar, and choose equipment with a vibropress. The slag obtained from coal processing is an ideal filler for blocks, but today production volumes have decreased due to the active use of gas, so it is not always possible to get the slag. In this case, zitoconcrete will serve as a worthy alternative, but its cost is much higher.
Zitoconcrete is more expensive than coal slag, but when compared with other materials, the benefits are obvious. If you make elementary calculations, it turns out that for the manufacture of one cinder block, you need to spend 0.011 cubic meters of cement (1: 7 solution). Based on this, one package of cement is enough to make 36 cinder blocks, which is already a lot.
The recipe for the “correct” solution for cinder blocks is very simple - you need to mix 7 parts of coal slag or zitoconcrete, 2 parts of crushed expanded clay, 2 parts of gravel 5-10 mm in size, 1.5 parts of high-quality cement not lower than M400 and dilute all with three parts of water. As an alternative to the filler, you can use gypsum, ash, expanded clay, gravel, sand, brick and coal mining, perlite. By adding different ingredients, you can control the strength, weight and thermal efficiency of the material depending on the desired result.
Useful advice: to check the quality of raw materials for the production of cinder blocks, scoop the mixture with your hand, squeeze it into a lump and throw it on the ground - if the solution sticks together well and crumbles from hitting the ground, then the components are mixed in the correct proportions.
If you are going to set up the production of cinder block at home, you will have to find your own recipe for making the mixture, because there are no universal methods. Stick to the standard recipe above and vary the amounts and types of ingredients to your liking.
The only thing that should not be changed is the established shape and dimensions of the products. In construction, cinder blocks with dimensions of 39x19x20 and 40x20x20 are used. Solid cinder blocks have increased strength, so they can be used to build a foundation, basement or basement. Hollow materials make warm and soundproof walls.
cinder block manufacturing
In domestic construction, two methods of producing cinder blocks are practiced - using home-made wooden matrices or special equipment. Of course, you can buy molds for cinder blocks, but if you can easily make them yourself, why spend extra money?
wooden forms
In general, molds for cinder blocks can be made not only from wood, but also from metal (galvanized sheets or other material). However, since wood is the cheapest and most common material, we will focus on it.
Since the standard size of a cinder block is 40x20x20 cm, the form must have the appropriate parameters. The cell where the solution will be poured consists of a bottom and walls. To save material and your own time, you can make a large form with a single frame, divided by crossbars, forming cells of the desired size. The width should not exceed 2 m, otherwise it will turn out to be too bulky and uncomfortable. The price of molds for cinder blocks in hardware stores is often unreasonably high, especially when you consider how easy it is to make it yourself from improvised materials.
Crossbars can be made of wood, like the frame itself, but it is better to combine wood and metal. For example, make the frame from moisture-resistant plywood, and the walls of the cells - from sheet metal, cut into strips. By the way, the form does not have a bottom, so the intermediate elements should be fastened together with the help of cuts, joining each other. Make a formwork without a bottom and saw through the boards so that it is possible to insert the transverse elements into the longitudinal ones and fix everything with a single frame (frame). You will get a collapsible design, from which it is easy to remove finished blocks.
The structure is laid on a clean, flat surface covered with plastic wrap or cellophane. The boards are painted with oil paint so that the solution does not stick to them, and the blocks easily move away from the mold before the mixture hardens.
It remains only to fill the form with the prepared solution and tamp it well. To make a hollow block, glass bottles are inserted upside down into the solution, excess solution is removed and the surface of the block is leveled. After 5-6 hours, the bottles are removed, and voids remain in their place. The blocks are dried for 24 hours, after which they are taken out of the mold and stored in piles.
Homemade machine "Laying hen"
If you are going to build a large house, several facilities, or want to start your cinder block business, then you will have to make a machine, because the above form will not be able to provide enough finished material.
The best option is a machine with a vibration device, which allows you to produce large volumes of cinder blocks without waiting for the solution to solidify. This is explained not only by the special principle of operation of the mechanism, but also by the thicker consistency of the solution - for this, a hard, viscous solution should be made, which gives less shrinkage when dried.
There are 2 methods of mechanized production: using a vibrating table, as in the image above, or using a homemade cinder block mold equipped with a motor with a center of gravity shift on the shaft. The latter method is more convenient, since it allows you to immediately make solid formed blocks without turning the shape over.
We propose to consider the process of assembling the simplest Laying machine. Below you can see the drawings of the mold for the cinder block - the machine is a molding matrix without a bottom and a vibrator attached to the sidewall. It also has handles that help to easily remove the matrix without damaging the integrity of the still raw block.
Making a homemade machine for cinder blocks:
- The standards provide for certain dimensions of the product, the voidness should be no more than 30%, otherwise the bearing capacity of the block will suffer. To make a matrix, use sheet metal 3 mm thick or more. Cut a fragment in the shape of a cinder block, adding 5 cm from the top to tamp the mortar. As a result, you should get 2 matrices 40x25 cm in size, 2 pieces 20x25 cm, 4 ribs 4x4 cm in size, a visor 40x15 cm and a clamping element 39.5x19.5 mm.
- Make a through form without a bottom from blanks measuring 40x25 and 20x25 cm. Use a welding machine to connect the parts. Weld the seams on the outside so that the metal does not lead.
- To make the matrix more stable, weld strips cut from thin shaped pipes with a diameter of about 8 cm at the ends. The length of each blank is 25 cm. Place these blanks inside the mold in one row at an equal distance from the walls of the mold and from each other.
- Weld the pipe sections to the matrix and fasten them together using blanks 4x4 cm in size, placing them in the upper part.
- Make a rubber upholstery around the perimeter of the base to protect the shape from deformation.
- Make a fringing apron that will not allow the solution to crumble while filling the form.
- Attach a vibrator to the long side of the almost finished machine. As a vibrating device, you can use a low-power electric motor from an old washing machine (100-150 W will be enough). Make an offset by attaching an eccentric to the shaft. The parameters will have to be calculated empirically, since too large dimensions and weight can create vibration that is detrimental to the workpiece, and the cinder blocks will simply fall apart. Fix the motor with bolts, and weld them to the matrix by welding.
- Attach a canopy over the vibrating device to prevent water or grout from entering the motor.
- Attach a support leg to the edge of the protective visor - it will give the machine additional stability, which is simply necessary due to the shifted center of gravity.
- Weld the handles for removing the matrix.
Voids in cinder blocks can be made in various shapes, but they must be cone-shaped so that the matrix can easily move away from the solution that has not yet solidified. Elements for punching in a block of voids can be made from round pipes turned on a lathe.
Now you can start producing blocks. To do this, the matrix should be moistened with cold water so that it can easily come out blindly without damage. Fill out the form and turn on the vibrator for 5-7 seconds. This time is enough for the mixture to shrink. Add a little more mortar, start the motor again and wait for the clamp to stop - this will mean that the molding has come to an end. After 5-10 sec. the matrix can be removed without turning off the device.
Helpful Hint: To get a perfectly smooth block face, lay the casts out to dry on a rubber mat.
The blocks dry from 7 to 20 days, depending on the humidity and temperature of the air, as well as the raw materials from which they are made. With the help of this simple machine, two people in an hour without much haste will be able to produce from 40 to 70 blocks, which, you see, is a lot. In a day, you can safely make as many blocks as you need for construction, of course, if there is where to place them to dry.
The cheapest vibrating machine for the production of cinder blocks will cost about 10-15 thousand rubles. For this money, you can buy several bags of cement with other necessary components and make cinder blocks that are enough for a whole garage! The ability to create a form for cinder blocks from improvised materials will save you an impressive amount, and the realization that time and effort has been invested in each brick of the house will make the result of the work even more valuable.