A house from a home-made heat block is a variant of a budget construction project from a portal craftsman. How to choose the right equipment for the manufacture of heat blocks with your own hands? Do-it-yourself installation for heat blocks

Summary
About technology
Advantages

Mini business organization:
Turnkey construction as a service
Production of heat blocks for small construction teams
Mini plant for the production of heat-insulated materials and turnkey construction

Business equipment:
room
Staff
Equipment for the production of heat blocks

Financial plan:
Investments in mini business
Payback periods

Summary:

About technology.
Modern construction technologies make it possible to manufacture a variety of energy-saving materials for capital construction. Materials for prefabricated technologies are currently in demand no less than high-quality energy-saving raw materials. And the competitiveness of any building material increases under the condition of low cost.

Heatblocks are unique Russian technology for civil construction, mainly low-rise, combining the most relevant factors of competitiveness.

Advantages.
The block is a three-layer system (claydite concrete, expanded polystyrene, external finish of dense concrete) with exterior trim, that is, they combine external aesthetics, energy saving, reliability and low cost of construction. The speed of construction of buildings from heat blocks reaches 1 sq. m in 20 min. Construction does not require special building qualifications, so the system can be applied in self-construction.
Construction costs are reduced by:
- masonry walls in one row, chain method;
- reduce consumption cement mortar(37 m2 = 1 m3 of cement mortar);
- there is no exterior finish as a separate process;
- reducing the cost of mason's work;
- reducing the load on the foundation allows the use strip foundations;
- transportation costs are reduced due to weight reduction (2-3 times) in comparison with brick wall;
- the usable area of ​​the house increases (a house of 10 * 10 meters will have an area of ​​​​15 square meters more).
The proposed technology is able to meet the demand in the construction market and provide inexpensive building materials that are significantly superior to existing ones, while reducing the overall labor intensity of both production and construction. In general, it can be used as a production basis for the work of construction teams. Heat blocks can be used in low-rise construction (up to 5 floors), without limiting the number of storeys - in frame construction.

Organization of mini business.
The business for the production and sale of heat blocks can be deployed in several formats, which imply different features and positioning in the sale of products.

Turnkey construction as a service.
The equipment for the production of heat blocks can be purchased by a professional team that wants to expand its range of services. The essence of the proposal and its competitiveness is that when using its own raw materials, the team can provide turnkey pre-fabricated construction services, subject to an increase in the rate of return and a decrease in labor intensity. Heat blocks allow you to optimize construction costs and reduce labor costs while maintaining other indicators of construction quality. At the same time, the client receives a lower cost for an energy-saving house, provided that it is built in a few months.
With an 8-hour working day, on average, a team can lay out walls with a total area of ​​​​25 square meters. m, respectively, to ensure the work of the brigade, you will need equipment that allows you to produce about 25 square meters. m.

Production of heat blocks for small construction teams.
The production of heat blocks can be set up with the expectation of working with professional construction teams and private traders involved in self erection cottages and low-rise construction. In this case, you can purchase equipment in a minimum configuration that allows you to produce up to 5 square meters. m per day. This is quite enough to start a business with expansion opportunities.

Mini plant for the production of heat-insulated materials and turnkey construction.
If desired, equipment for the production of heat blocks can be purchased. There are automated lines for the production of 50 cubic meters. m of heat blocks per day. Such volumes of production make it possible to build houses on a turnkey basis with the help of our own teams and sell them at retail.

Room.
To install equipment for the production of heat blocks, you will need a room with an area of ​​​​about 500 m, this is a universal area on which a complex for the production of 20 cubic meters can be deployed. m per day or more. With a small set of equipment, the room can be used as a warehouse for finished products, palletized products can be stored outdoors.
In fact, the room is a production workshop for the production of concrete products, therefore it can be equipped in accordance with the standard requirements for reinforced concrete products.

Staff.
The staff serving the mini-installation does not exceed 5-7 people (20 cubic meters), with an increase in labor intensity and production volume, the number of personnel can be increased to 20 people.

Equipment for the production of heat blocks.
The most optimal investment option, which allows for the fastest payback, is designed for the production of 20 cubic meters. m of heat blocks per day. Here is a set of equipment required for production:
- a vibropress for the manufacture of 15-17 cubic meters. m of heat blocks with a size of 400 * 140 * 400;
- vibrating chair with clamps for additional blocks sized 200*800*750;
- a table for cutting polyfoam - 2 pieces;
- several types of plastic molds;
- plastic molds for half blocks;
- formwork for the production of corner blocks sized 250*190*450, 36 sets;
- universal swing formwork;
- metal plate for openings;
- formwork remover;
- chipboard trays for vibropress.
The cost of such a kit is about 800 thousand rubles.
Additionally you will need:
- equipment for cutting foam - 100-130 thousand rubles;
- loader - 100 thousand rubles;
- steam generator 60 kW - 100 thousand rubles;
- racks;
- steaming chamber.

A semi-mechanical vibropress with equipment will cost about 1.6 million rubles. The semi-mechanical line can produce a range of concrete products as well as other types of blocks such as sand blocks.
It must be said that it is much more profitable to purchase a new set of equipment than a ready-made business, since establishing business contacts is not difficult due to the high demand for products. The cost of a ready-made business with installation according to brokerage companies for the production of 20 cubic meters. m per day costs an average of 3 million rubles.

Financial plan.
Here is a financial plan that allows you to evaluate the efficiency and profitability of the business:
- the cost of new equipment without transportation costs to the region is about 850 thousand rubles;
- price additional equipment- 350-400 thousand rubles;
- the cost of renting the premises - 60 thousand rubles with utilities;
- the cost of a heat block is about 55 rubles, the cost of implementation is 165 rubles;
- productivity - 640 blocks per shift with an 8-hour working day (20 cubic meters);
- revenue with 24 working days is - about 2.5 million rubles.
- income - 1.6 million rubles;
- average annual profit - 400-500 thousand rubles a month.
The payback period, even with the purchase of a ready-made business, ranges from six months to 1 year. On average, we can talk about the payback of the business for the production of heat blocks during one construction season.

Investments in mini business.
Investments in a mini business are ways to invest in a business that do not involve personal labor costs, but allow you to become the owner of a business and earn income. At the moment, there are a number of brokerage companies offering to invest in other people's mini-business, thus, cooperation is achieved - when one partner invests his own labor, the second - financial resources. Thanks to brokerage companies, it is possible to invest businesses located throughout Russia, thus forming a whole package of portfolio properties.

Payback periods.
Despite the fact that the real payback period can be one construction season, it is necessary to take into account poorly predictable risks and the slow adaptation of the owner to new activities, so you should really count on the payback of a mini business for the production of heat blocks within 2-3 years. The minimum payback period is 6 months.

Marketing.
The marketing policy of a mini business for the production of heat blocks significantly affects the payback period. In general, positioning and promotion of products entirely depends on the format of the chosen business. On the one hand, it is necessary to popularize the new construction technology and its advantages. This information must be conveyed to the general public, for this, appropriate advertising methods are used.
In the first case, during the work of a team that provides itself with building materials, it will be necessary to promote the construction of turnkey energy-saving houses. The technology must be compared with the construction of wooden and Canadian houses. The main feature is fast construction.
In the second case, when equipment is purchased for the sale of heat blocks, agreements must be concluded with construction teams and shops.
The third format involves the composition of the measures of the first two cases to attract customers. An effective approach is the conclusion of contracts with settlements in which construction work is underway.
You can also talk about an effective individual business, which involves the production of blocks for personal purposes. Income is generated by building a house with a view to selling it later. Mini installation for the production of heat blocks allows you to reduce the complexity of construction and the cost of materials.

Advertising.
It should be noted that the consumer is quite distrustful of new technologies, so the popularization of new construction technologies will be required. An important point there will be cooperation with the teams that carry out construction work.
Advertising methods include prime-time radio and television advertising, newspaper publications on the virtues of technology, Internet advertising, and your own website.

Sales of products.
Sales of products are carried out in accordance with the chosen marketing policy, common features and features of which are described in this review. The technology is new, uncommon and competitive, which guarantees its success with potential buyers. At the same time, the payback period depends on the activity of the owners.

Manufacturing technology of heat blocks at home, subtleties of application, living experience

The portal has repeatedly talked about a relatively new composite masonry material - heat blocks, but it was about factory products. It turns out that at home you can get material with decent characteristics and half the price. One of our craftsmen was convinced of this, who built a house from heat blocks of his own production. In his topic, he talks about the intricacies of technology, the features of masonry and the sensations of living.

• Production of heat blocks

Production of heat blocks

Heat-efficient blocks (heat blocks, polyblocks) are a three-layer product, with a structural layer most often made of lightweight concrete, mainly expanded clay concrete. The thermal insulation layer is usually made of expanded polystyrene, less often extruded polystyrene foam. External, decorative layer - textured, dyed in mass or natural gray color, in the first case, the facade after masonry does not require finishing, in the second, painting is necessary.

The craftsman made the choice in favor of the heat block due to a fortunate combination of circumstances.

Zzaur FORUMHOUSE member

I am a professional programmer, I had no relation to construction before. But, nevertheless, when I had to build a house, I decided to design and build it myself. My father, the Internet and hands helped me with this. Why polyblock - yes, because I accidentally got molds for casting, a vibrating table, a concrete mixer and a table for cutting foam - the whole set for self-produced polyblock.

Also lucky with summer cottage, obtained back in the days of the Country of Soviets on the outskirts of the city, and now overgrown with buildings and found themselves very much in line.

To make the house as reliable, durable and heat-efficient as possible, the craftsman decided to cast blocks 40 cm thick, with a structural layer of heavy concrete filled with crushed stone of medium fraction. The Stavropol Territory has rather mild winters, so he considered that the PPS thickness of 150 mm was more than enough. When creating the project, the ordering showed that the house would require about 1250 blocks - ordinary and corner. For those who plan to calculate the number of blocks in the future, we recommend doing calculations in Excel.

Consumables

• Cement M500 - 4.5 tons (3 Big bags).
• Crushed stone - 1 car.
• Sand - 1 car.
• PSB-S-25 (1000 × 1200 × 150 mm) - 20 m³.

The dimensions of the styrofoam boards were chosen to minimize waste, the size of the insert used in the block is 150x20x40mm.

The purchased sand, crushed stone and cement were enough not only for the blocks, but also for the foundation strip, wall plastering, floor pouring and still left for the fence.

By purchasing in bulk, it turned out to save a lot on materials. Block strength Zzaur I picked it up empirically - I experimented with proportions, molded a block, and took it for examination. I settled on a solution that gives M50-75 strength at the output, enough for a one-story house with wooden floor. The blocks were tested in finished form, with a foam layer.

Proportions

For one mold filling of 12 blocks, the following batch:

• Cement - 2 buckets.
• Granite crushed stone - 6 buckets.
• Sand - 11 buckets.

For additional fixation of the foam for each block, I used two pieces of fiberglass reinforcement (diameter 6 mm, length 20 cm). To add texture natural stone used reusable liners.

Zzaur

The form is installed on a vibrating table, after pouring with concrete it vibrates for 10-15 seconds, after the rokhle you drag the form a few meters, cover it with a film, and the next day still warm blocks are placed on the wall. Expanded polystyrene was cut on a cutting table, a cutting table and a vibrating table were welded from sheets of metal and corners, a vibration motor (4000 r) was welded to the vibrating table from below, and an incandescent string was attached to the cutting table through the LATR.

Before pouring, the molds were leveled, in addition, they turned out to be made of high-quality metal with “memory”, which made it possible to obtain an almost ideal geometry of the blocks with a deviation of 1-2 mm. In the future, this helped to save the masonry mixture due to a thin seam. Corner blocks are made in the same forms, only the liners used for the front side differ, and to obtain "halves" a metal plug is installed in the form.

A block wall is lighter than a monolithic one - although the weight of one block is about 40 kg, due to heavy concrete, the total mass of a cubic meter of wall is about 1100-1200 kg. The cost of the block is approximately 85-90 rubles, while the factory price is around 200 rubles, in addition, there are no costs for delivery and unloading, and storage space is not required.

Construction of a house from heat blocks

As a programmer Zzaur“on a short footing” with a computer, the project of a one-story house with an area of ​​96 m², with dimensions of 10 × 11.2 m, with order, developed independently.

After the development of the project, the craftsman calculated the thermal characteristics of the block and the dew point, as the calculations showed - the heat block passes through all parameters.

The foundation for the house is tape, buried by 1.2 m, all the draft floors are cement, on the ground, after they have been poured and cured, equipment was installed inside the building spot and the laying of walls began. In the evening, all five molds were poured, after lunch the blocks were carefully removed, still warm, and immediately went to work. It turned out a vicious cycle - while the new batch was solidifying, the craftsman with an assistant just had time to use 60 blocks of the previous one. Masonry on the finished "warm" mixture, above the door and window openings a metal corner (75 × 75 mm). You can get by with an ordinary mortar, and make the seam thicker, the masonry itself can be done by a non-professional.

Zzaur

1. You can also put it on the DSP, if you follow the technology, then there are no problems, and a seam up to 2 cm does not spoil the view at all. I also used the DSP, only “warm”, in bags - both red tape and less garbage, spread it in a bucket and went to work (it closes easily and with a trowel, only my hands get tired)
2. A seam from 0.5 cm to 2 cm looks like a bomb, I have 1 cm.
3. There is nothing difficult in the masonry itself (I laid it myself), if I have enough strength to lift and hold the block - my heavy one (42.5 kg) is due to crushed stone, if the expanded clay concrete block (27-30 kg) is even easier and faster. The main thing is to observe the level and monitor the plumb line.

Manufacturers of heat blocks recommend embroidering the seams and sealing them with sealant, instead of jointing, the craftsman went through fresh seams with a stiff brush - he immediately removed splashes from the front of the block. He did without sealant and does not regret it, but it is possible that they save large offsets - 80 cm, only oblique rain in a strong wind gets out.

The box, from laying the foundation to the roof, was built in four months, two of which went to the walls.

The next stage was the plastering of the walls, the finishing floor, the electrics, plumbing and sewerage. I made strobes for electrics with a drill, the whole house went through in a day. Holes for bolts for fastening double-glazed windows pre-drilled. Heating is gas, from a double-circuit boiler, therefore, a separate boiler layout is not provided.

Now it has become very fashionable to build houses from heat-efficient materials. Moreover, this is a very good solution, which allows you to save significant amounts on energy resources to maintain comfortable temperature conditions in the house. One of these materials is a heat block.

This name hides a modern building material, which is ideal for the construction of structures with high thermal performance. Reviews about you can hear mostly positive, which contributes to a very rapid growth in demand for it. Its main advantages are high thermal efficiency, excellent appearance and a very reasonable price.

The heat-insulating properties of the heat block are due to its unique design. The fact is that this product is not monolithic, but consisting of three layers:

1. The inner surface is made of expanded clay concrete, which acts as a load-bearing wall.
2. The middle layer is expanded polystyrene, which plays the role of a heat insulator.
3. The outer layer is a lining and performs a purely decorative function.

The production of a heat block can take place both on high-tech expensive equipment, and with your own hands using simpler devices.

They depend on various factors: on what equipment they were made, how high-quality components were used and the cost of the product.

Technology for the manufacture of heat blocks

As mentioned above, this material consists of three layers, each of which performs certain functions. In order to combine all these three components together, several steps are necessary:

1. First you need to prepare the solution in a special mixer. To do this, all the necessary components are added there: sand, expanded clay gravel, cement, chemical additives and water.
2. Install the polystyrene insert manually in the matrix. At the same time, it is necessary to make sure that its position exactly coincides with the protrusions on the insert itself and on the matrix. It should enter tightly, but without effort. After installation, it is not allowed that the liner protrudes beyond the bottom edge of the form.
3. The prepared solution is poured into the matrix.
4. The mixture thickens.
5. The compacted material is placed in a thermal chamber for complete drying.
6. The product is removed from the matrix and sent for packaging (in the case of manufacturing for personal use - to a temporary storage place).

It is worth noting that two methods of compacting the mixture in the mold are now used: vibrocasting and vibrocompression.

Production by vibrocasting is as follows: after filling the matrix with a mixture, it is placed on a vibrating table, where, with the help of intense vibration, it is evenly distributed throughout the mold, followed by compaction. After some time, the solution will harden and the heat block can be removed. To speed up the hardening, you can use special additives.

Production by vibrocompression requires more sophisticated equipment. In this case, a vibropress is used instead of a vibrating table. To do this, the semi-dry mixture is poured into a special mold of the vibropress, where it is compacted by a punch with simultaneous vibration. After that, the resulting material is sent to a heat chamber, where it gains strength. This method has a greater productivity and degree of automation, which reduces the influence of the human factor on the quality of the product.

Equipment for the manufacture of heat blocks

In the production of these building materials, the equipment is selected depending on the chosen technology and manufacturing conditions. For industrial production in the conditions of the workshop, it would be optimal to purchase expensive equipment in which most processes are automated. The best choice there will be vibropress equipment. It will allow you to produce high-quality products at a minimum cost.

The price of such a line with a capacity of 20 m 3 per day will be about 70 thousand dollars. But this is an approximate cost, which may vary depending on many factors.

If it is planned to manufacture heat blocks at home using own hands, then here you need to look for simpler equipment that has a low cost. In addition, an important condition is the simplest and most compact installation possible.

Foreman's advice: do not forget that the equipment must be powered from somewhere. Therefore, when choosing it, it is necessary to pay attention to the possibility of working from 220V.

You can get by with just a concrete mixer and molds, but then productivity will be extremely low. And the quality of the products will be far from perfect, because the degree of compaction will be low. In addition, without a heat chamber, the drying process will take 8 hours versus 4 in it.

But if you can still do without a thermal chamber, then the vibrating table will greatly facilitate the manufacture of heat blocks and increase labor productivity. So, the minimum set of equipment will cost approximately 2-4 thousand dollars.

During construction, you can significantly save on materials if you make them at home. To do this, it will be enough to purchase the simplest installation for the manufacture of heat blocks.

Video

Far from being the simplest production of heat blocks requires the use of a carefully verified recipe for the concrete base of the blocks and the technology of forming polyblocks. Nevertheless, it is quite possible to make heat blocks with your own hands in semi-handicraft conditions, if you do not save on equipment and consumables.

Technology for the manufacture of heat blocks

The main difference in the production of heat blocks lies in the method of obtaining a concrete bearing base or a durable layer. For home-made three-layer blocks, three process options are used:

• Vibrocompression of concrete mix;
• Formation of heat blocks by ordinary casting of concrete into a prepared form;
• Manual gluing of heat blocks from separate layers.

Note! All three methods differ in cost, quality, accuracy of geometric dimensions and strength of the resulting blocks.

Therefore, the choice of technology for the production of heat blocks directly depends on their further use and the availability of equipment.

For example, for a small one-story house, a polyblock made on a rented vibrating press is suitable. Full-fledged two-three-story cottages are built from cast sand-cement heat blocks. To finish the facade with an expensive type of tile, tiles made of natural stone or porcelain stoneware, the technology of manual gluing of blocks is used.

Features of the production of heat blocks with their own hands

There are many expert opinions that defend the advantages of one or another method for the production of three-layer polyblocks with polystyrene foam insulation. Their statements should be treated with a certain degree of skepticism, since most judgments are made on the basis of the quality of the received single handicraft products, without taking into account and analyzing the compliance of handicraftsmen with all the requirements of the technological process.

Important! If the technology is strictly observed, without adjustments for local features, then with any manufacturing method, the heat blocks are strong and durable.

This was proved both by Finnish technologists and European experience in the construction of residential low-rise buildings from a three-layer material.

Equipment for the production of heat blocks

It makes sense to engage in the production of composite concrete blocks only if it is possible to rent or buy high-quality equipment for the production of thermal blocks. On average, the payback of a line for stone is at least six months with 80% of the machine park.

It is possible to produce solid heat blocks with your own hands only in single copies, no more than 3-5 pieces per day. With such an organization of production, the cost of a block will not be 260-270 rubles. per stone, and all 300 rubles. with significantly lower mechanical characteristics.

For mass production of heat blocks, vibrocompression technology is used. This is the best option. The Monolit line shown in the photo is capable of producing several thousand high quality polystyrene blocks.

For handicraft production, hydraulic vibropresses or the simplest manual machines with mechanical drive. In this case, the technology for the production of heat blocks does not change, only the method of creating force is different - with the help of an electric motor or by hand.

The injection method of production provides for automatic preparation of the mixture and pouring molds with a foam insert laid inside. Forms with filled heatblocks harden and stand in heat at a temperature ranging from +5 to +45 o C. Forms for pouring are usually assembled in packages of three pieces in a row.

In addition to molds and press equipment, you will need a machine for making foam inserts, or you will have to cut polystyrene bricks with hot wire.

Production of heat blocks on a vibropress

Most of the claims are made against heat blocks made by vibration pressing. The main list of claims is as follows:

• Low mechanical strength of expanded clay concrete;
• Poor adhesion of decorative stone or concrete with a foam insert, which causes delamination and accumulation of moisture inside the polyblock;
• Large error in the geometric dimensions of the heat block.

The strength of a heat block with an expanded clay concrete layer is indeed lower than that of a block with a cast sand-cement mixture. In the latter, the strength of the concrete casting reaches class B12 or M150. When using expanded clay, the heat block loses up to 60% of its original strength, but still the material is twice as strong as the same aerated concrete.

Problems with poor adhesion or polyblock geometry only occur when the foam liner is not prepared or the vibrocompression is done by hand.

Note! To compact the form of a heat block with expanded clay concrete, much more time and a higher frequency of the vibrator are required.

The process of manufacturing a heat block on a machine with an electric or hydraulic drive consists of the following steps:

The process of manufacturing heat blocks is highly dependent on compliance with the conditions of hardening. Expanded clay polyblocks with foam insulation withstand two days in a warm and humid atmosphere, only in this case there will be no cracks or chips on the surface. Cement-sand heat blocks withstand up to 20 days at a positive temperature and regular surface moistening. Sometimes in the process of home production, the conditions for holding the material are neglected, as a result of which cracks appear in the concrete.

Production of a cast heat block

The technology for manufacturing blocks by casting practically does not differ from the manufacture of reinforced concrete slabs, with the only difference being that the compaction of the cement-sand mixture in the metal form of the heat block is significantly higher than that of expanded clay concrete models.

The form with the installed foam insert and fittings is mounted on a vibrating table and poured with concrete. The secret of the high strength of cement-sand heat blocks is the use of special plasticizers that ensure the removal of air bubbles.

In contrast to the vibropress technology, when concrete is poured into the mold simultaneously from both sides of the insert, in the casting scheme, the layers are laid sequentially. The mass is in the form until the set of residual strength. It is not very convenient, since it is possible to release the equipment without damage to the structure of the polyblock only on the second day.

Accordingly, if you plan production in artisanal conditions, you will need to stock up plastic molds in a double set, but still, the daily output usually barely exceeds 50 blocks.

It is possible to make three-layer stones even in conditions where it is not possible to purchase or buy suitable equipment for heat blocks. The poured mixture is compacted with a manual tamper, or fabric liners are placed in the mold, and the solution is kneaded with an excess of 15% of water. If the casting of a three-layer block is kept not for 1-2 days, but for at least four days at a temperature of 10-12 ° C, then the strength of the polyblock will be no worse than after the vibrating table, however, with higher shrinkage.

glue blocks

In addition to foam plastic and concrete, mineral fiber, XPS, polyurethane foam and even foam glass are actively used in production. For mineral and basalt fibers, XPS can be cast without separation of layers, according to the usual scheme. But in this case, the polyblocks are not strong enough, so in piece production they are often glued with acrylic mixtures.

A similar method is used in situations where natural stone tiles are used for exterior decoration. In order not to risk the material, marble limestone, gabbro and even certain types of ceramics are most often glued onto an already finished stone.

Production of liners for heat blocks

For a small batch of polyblocks, embedded inserts can be made with a conventional wire cutter from nichrome wire. If a we are talking about the production of several hundred three-layer blocks per day, you will need a special slot machine, as in the video

Inside the double-walled box there is a wire profiled contour. The blank of the liner cut to size, passing through the hot template, receives the required profile of the grooves.

After passing through the hot wire, the surface of the foam does not melt, as when cutting with a hand tool, but acquires a dense and rough texture. If the liners have to be cut with a hand tool, then the foam surface is pre-treated with a primer before pouring.

Forms for heat blocks

A standard mold for a vibropress machine is made of metal according to a box-shaped scheme with a quick-detachable bottom. The box is fixed on the bed of the press and set under the dimensions of the movement of the punch. The loads on the walls of the form are relatively small, so the service life of the fixture can be hundreds of thousands of pieces of the heat block.

For vibrocasting, collapsible molds made of high-impact ABS plastic are used. The material easily withstands prolonged heating up to 75 ° C, so the polyblocks can be kept in the steaming chamber.

Vibropress for heat blocks

One of the most interesting options equipment for production at home is considered to be a universal vibropress VP600. With a mass of equipment with equipment of just over 180 kg, the press is able to form a full-fledged block weighing 30 kg in 30 seconds.

More powerful equipment, for example, vibropress VIPR1-2M, provides production at the level of 50-60 polyblocks per hour.

Machine for heat blocks

For home production of polyblocks, the use of vibropress equipment VP600 or VIPR turns out to be too energy-intensive and expensive to maintain. Simpler and cheaper fixtures and machines provide acceptable performance in terms of the number of polyblocks at a minimum price and energy consumption.

The simplest version of the machine for the production of blocks is shown in the photo.

The design is a vibrating table with a frame on which movable consoles with pressing punches are fixed. The table is driven by a 500 W electric motor, which is quite enough for vibrating compaction of heat blocks 600x300 mm in size.

For laying and removing the mold, the machine design uses a rolling cart, while the equipment is designed for a load of 300 pieces of a block per day.

Business plan for the production of heat blocks

The selling price of a branded three-layer block is 260 rubles. To receive permanent orders, the cost of a block 40x30x20 cm should be no more than 250 rubles. with a thickness of insulation of 100 mm, a solid base - 150 mm, decorative cladding - 50 mm.

Accordingly, the cost of materials for the production of ten polyblocks will be:

• Cement-sand mixture - 170 l or 350 rubles, in the manufacture of the batch on their own;
• Expanded polystyrene insert 40x20x10. The cost of ten foam inserts will be equal to 150 rubles;
• A decorative stone for ten pieces will cost 100-120 rubles.

In total, the cost of materials for the manufacture of ten blocks will amount to 600-620 rubles.

In addition, the cost of a set of forms is another 10,000 rubles. Price most simple machine for heat blocks - 85 thousand rubles. In total, the cost of producing the first commercial batch of 500 pieces will amount to 30 thousand rubles. for materials and 95 thousand rubles. for equipment. The proceeds from production will amount to 125 thousand rubles.

Conclusion

The production of heat blocks, using high-quality equipment and materials, is considered a highly profitable business. It will take at least three months for the project to pay for itself, after which the production will bring a steady profit, provided that at least a thousand polyblocks are sold per month.

A finished house in two weeks or why we are interested in heat blocks

The world is rapidly evolving, isn't it? And along with changes in the surrounding space come new needs. We all want convenience and comfort, but most importantly, today we can afford it. To live in warmth and comfort, you no longer need to heat the stove and close the gaps between the logs with moss. You don't have to spend decades building big, draughty stone houses, giving rise to legends about ghosts, to know that your house won't burn down and dry out. But most importantly, the outdated stereotype that comfort should be an expensive pleasure has long outlived its usefulness.

The only problem in construction that we face today is selection of quality building materials. The market is replete with many budget and not very options for wall blocks and bricks. Almost all of them have their advantages and disadvantages.

But in this article we want to talk about a fairly young and interesting type of building material, which combines at once everything you need to build a house.

What are heat blocks

Imagine how much easier the construction process would be if residential buildings were built as easily and quickly as Lego brick houses? At the same time, the cottages could be warm and beautiful, and the whole process did not take more than a couple of weeks. Do we surprise you if we say that such material already exists, and hundreds of people have acquired houses from it?

Heat blocks- a type of wall blocks manufactured using a special technology that allows you to combine three layers of material at once. Therefore, heat blocks have an alternative name - polyblocks, and since they have high thermal insulation characteristics, the name “heat-efficient blocks” is found.

The technology for the production of heat blocks came to us from Finland. The pioneer was the company Lakkan Betoni - founded in 1965. For 40 years, Lakka materials have been used to build houses throughout Finland and beyond.

Our Western neighbors value economy and quality, so the technology has spread throughout Europe, and Russia, partly due to the cold climate, heat blocks have found their devoted consumer.

One of the leaders in the market for the production of heat blocks in Chuvashia and Russia is the company Polyblock-Stroy LLC. Since November 2015, the company, which has been manufacturing heat-efficient blocks for more than 10 years, has become part of the Cheboksary Construction Plant, and from that moment, our close cooperation began.

Technology for the manufacture of heat blocks

Multilayer heat-efficient blocks are construction material, combining in one block:

· bearing layer of expanded clay concrete;

a layer of insulation made of expanded polystyrene impregnated with a refractory composition;

and a facing layer with a different version of the texture.

The layers are securely fastened with strong basalt-plastic reinforcement. But, let's see what each represents.

Facing layer

In the production of heat blocks, a facing layer is first poured into the matrix.

The form, the pattern of which forms the texture of the future block, is placed on the bottom of the matrix, where the claydite-concrete solution is poured.
For the manufacture of the mixture, the following components are used:

expanded clay (thanks to it, the thermal conductivity of the block is reduced and cold bridges are eliminated);

cement brand M500;

river sand (it does not contain clay impurities, which reduces the quality of the material);

All ingredients are mixed in a concrete mixer, forming a homogeneous mass, which is poured into molding dies.

These matrices with expanded clay concrete mortar are installed on a special device - a vibrating table, which, by means of vibration, releases excess air from the solution, thereby contributing to the improvement of the geometry and quality of the block.

insulation

Expanded polystyrene used as a heater has a width of 16 cm. The indicator of the strength grade is M25. In the workshop, wide sheets of expanded polystyrene are cut with a hot thread into even pieces of the required size.

Styrofoam- it burns by itself, therefore, before using it as a heater, the workpieces are impregnated with a special substance - foam, which reliably protects the material from high temperatures.

The blanks are placed in a matrix with expanded clay concrete mortar. Two layers are pierced with basalt plastic rods.

Reference

Basalt plastic - modern material, which came to replace the metal fittings. Unlike its predecessor, basalt-plastic rods are not subject to corrosion and chemicals, and they also do not let the cold through.

Bearing part

Following the blank from expanded polystyrene, expanded clay concrete mortar for the carrier layer is poured into the matrix. All components are again compacted on the vibrating table.

The matrix with future blocks is transported to special curing chambers, where, under the influence of high temperatures, moisture evaporates from them and the concrete hardens.

Warm air circulates in these chambers, the temperature there reaches 60 degrees. Heating, on the one hand, provides a heating boiler, and on the other - diesel guns. Drying in the steam chamber is the first stage of the process in which the block acquires its strength.

The carrier layer takes on the main load from the floors, so it is the widest and strongest. Carrier layer width - 16 cm.

Already full-fledged heat blocks come out of the steaming chamber, but in order for them to solidify completely and acquire all the specified parameters, they need to stand for 28 days. That is how much time it takes for expanded clay concrete to gain strength.

The standard and most common type of block has parameters of 400x400x190 mm. But in our assortment there is also a smaller block 300x400x190. This option is ordered by those who build low-rise buildings, as well as warm garages and baths.

Additional blocks

The obvious thing is not immediately evident - how to build the corners of the house from such blocks, so much so that the insulation does not show through in these places and everything looks aesthetically pleasing.

In addition to the corners, there are window openings and doors, but you don’t need to worry about heat and appearance here, since special additional blocks are made especially for them, including:

Outer corner block

Inner corner block

block of window openings (double-sided and half);

Blocks of a doorway normal and half;

belt block

ordinary half block

When building wall corners, blocks are used that provide a closed loop (uniform distribution of insulation) around the perimeter of the entire house.

Here you need not to make a mistake and combine the insulation with the insulation and the bearing part with the bearing part when laying the material.

Dispelling the myths

People who are looking for building materials for their homes often do not trust new technologies and products. We fight against such mistrust solely due to the willingness to show and describe in detail the entire production process, as well as constantly conducting quality audits and testing the strength of the material.

The number of people who have built cottages and other objects from heat blocks is constantly growing, but despite this, many myths hover around them.

1. First of all, speaking about the disadvantages of heat-efficient blocks, people focus on polystyrene foam used as a heater. Indeed, foam plastic has a relatively low vapor permeability, but with due attention to construction details, the consequences of this property can be easily avoided by resorting to installation forced ventilation.

2. And again polystyrene foam. Someone does not trust this material, thinking that it is a fire hazard, however, we have already said and will repeat again that such fears are groundless. We would not take on the production of material that does not meet safety indicators. Even the claydite-concrete block of the Cheboksary Construction Plant (which is definitely not on fire) has a fire certificate. And the insulation for heat blocks is impregnated with a special composition that resists fire and contributes to the self-extinguishing of the material.

But that's not all, being sure that the three-layer blocks will withstand any test, we have already prepared a number of tests for them in the laboratory. What we will write about in our blog so that you can be sure of the quality of the material.

And as regards positive material properties, which is a fact that few people pay attention to. Do you, specifically you, the person reading this article, want to live in a house that does not meet environmental standards? We believe not.

The basis of heat blocks is expanded clay concrete, which, in comparison with many separate types of wall blocks, is considered one of the most environmentally friendly.

We wrote about testing the environmental friendliness of expanded clay concrete blocks, and we are preparing the same for polyblocks in the foreseeable future. But already now you can be sure that a house made of heat-efficient blocks will become your protection, and not a headache.

The photo shows an example of a house built from heat blocks. As you can see, using this material in construction, you can come up with a lot of ideas for planning a house, experiment with shape and geometry, and bring to life a variety of ideas.

Save money with heat blocks

Most importantly, heat blocks remain an economical material!

Most likely, while reading this review, you have already understood that a polyblock will help you save a lot on insulation and cladding. How much can at least a brick for facing such a house cost? Obviously, it will cost a pretty penny, do not forget to add shipping and waiting period. To install insulation, it is generally desirable to involve a team of professionals, which is a separate expense item.

Building from heat blocks is a constructive, economical solution for building a house. But, speaking of savings when using heat-efficient blocks, one cannot fail to mention facts that are not striking from the first time.

1. Foundation.
Yes, yes, it is him. The weight of a standard heat block 40x40x19 is 22 kilograms, the walls are built in one row using multilayer blocks, therefore, the load on the foundation is significantly reduced. For the construction of houses from heat blocks, a lightweight grillage foundation is used. At the same time, the bearing capacity of heat blocks reaches 4 floors, of course, using an armored belt.

2. Heating.
As we have already said, the width of the expanded polystyrene in the heat block is 16 cm. Expanded clay concrete is a warm material in itself, and basalt-plastic rods do not let the cold through. Thus, behind the walls of heat blocks you will be comfortable in any season, and as a result, you will save on heating.

3. Increase in usable living space.
This fact is indirectly related to economy, but still worthy of being mentioned. The small thickness of the blocks allows you to increase the free space. Suppose if you build a house with a size of 10x10, then the additional usable area will be 15%, translating into numbers - 15 square meters. meters, and this is a whole room.

4. Fast construction period.
The record for building a house from heat blocks is 5 days. But, in general, it takes about two weeks to build a box at home. After that, you can immediately proceed to the interior decoration.

5. Do-it-yourself house.
If you have free time resources and decide to build a house on your own, without the help of teams, then heat blocks will undoubtedly suit you, and in the near future a section with useful tips for construction, as well as we will help you choose the right solutions seminars and webinars that you can watch online. But we understand that time is now a scarce commodity. Therefore, we offer the services of our own masons, who specialize in the construction of polyblocks.

In general, heat blocks - great option for those who want everything at once, and at the same time know how to save money and are always looking for the best solution.

The combination of quality, aesthetic appearance and reasonable prices, in simple words, this is how heat blocks can be characterized.

The house you want to build, even if you don't have a lot of money to spare, can look like a cottage from a picture drawn by artist Thomas Kinkade.

At the same time, there is every reason to believe that the a house, even a two-story one, even within the city or not far from it, will cost less than buying an apartment.

For example:

The cost of a whole two-story house, taking into account: the cost of a block, mortar, masonry mesh, mounting foam, truck crane, transport, as well as together with the foundation and roof, is 2,300,000 rubles.

Recall that when building a house from heat blocks, neither cladding nor insulation is needed, so the house can be considered ready. Outside, the walls of the house from heat blocks can simply be painted.

The cost of an apartment in Russia, of course, depends on the region, for example, let's take Cheboksary (Chuvash Republic), where the cost of apartments is quite low compared to other regions.

So, an apartment with a total area of ​​​​70 to 100 square meters. meters on average Cheboksary costs from 4,983,000 rubles.

The average cost of apartments in Russian cities:

City	Cost, rub.)
Nizhny Novgorod	5 270 000
Moscow	19 400 000
Kazan	5 334 000
St. Petersburg	8 011 111

You can see for yourself that, paradoxically, building a house is cheaper. Ask yourself the question - do you want a spacious cottage, with a plot where children can play without risk, or realize themselves as, for example, a gardener, get a dog and finally build a garage next to the house?