Expanded clay concrete blocks have great thermal insulation qualities, are lightweight, and are extremely durable, making them an excellent building material. Building a garden shed, garage, or even a house can be accomplished at a reasonable cost and with great satisfaction if you make these blocks yourself.
Making expanded clay concrete blocks at home entails mixing a certain mixture, adding it to molds, and then waiting for it to solidify. Achieving the ideal ratios for your mixture is essential to making sturdy and dependable blocks. High-quality blocks that satisfy your building needs can be made with a few simple tools and necessary materials.
We’ll walk you through the entire process of creating your own expanded clay concrete blocks in this article. Everything will be covered, including the required supplies and equipment as well as thorough instructions and practical advice. This guide will assist you in getting great results whether you’re a novice looking to try something new or an experienced do-it-yourselfer.
Proportions for the mixture | Step-by-step instructions and tips |
1 part cement, 3 parts sand, 4 parts expanded clay, water as needed | 1. Mix cement, sand, and expanded clay. 2. Add water slowly to achieve a workable consistency. 3. Pour the mixture into molds. 4. Compact the mixture to remove air bubbles. 5. Let it set for 24-48 hours. 6. Remove blocks from molds and cure for at least 7 days. |
Adjust water based on humidity | Use a mixer for even consistency |
Optional: Add plasticizer for strength | Cover blocks with plastic sheeting during curing |
- Ingredients for expanded clay products
- Tools and equipment
- Step-by-step creation process
- With improvised means
- On a special machine
- Possible difficulties and errors
- Pros and cons of self-production
- What is the cost?
- Useful video
- Video on the topic
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Ingredients for expanded clay products
To create your own concrete and expanded clay blocks The following items are necessary:
- expanded clay;
- cement;
- sand;
- water;
- boards;
- metal sheets.
Selecting pure, sifted sand free of impurities is preferable. A high-quality Portland cement is also necessary to prevent cracking of the finished stone over time.
You will need one part of Portland cement, so it is best to use grade M400. It is preferable to use six to eight parts of expanded clay; the exact porosity of the final product you desire will determine this.
Typically, 350–500 kg of expanded clay are used for every cubic meter. Common ten-liter buckets can be used for measurement; the volume of one of these buckets, depending on the fraction, is approximately 3-5 kg of expanded clay.
Take two parts sand; its fraction should be less than 5 mm, and use that amount for the specified amount of expanded clay and Portland cement. One to one and a half parts water are used, but the amount is usually decided by this: water is added only until the mixture reaches the desired consistency.
Note: It is suggested that you add 1 part of fairy or washing powder as an air-entraining additive and for the mass’s plasticity.
Tools and equipment
Before you begin creating expanded clay concrete blocks by hand, you need to get all the necessary tools and supplies ready. It is acceptable to mix the mass in a traditional large plastic trough if only a small number of blocks need to be made.
Preparing an electric concrete mixer with a capacity of at least 130 liters is recommended if you intend to produce a large quantity of stone. This equipment will speed up the process.
Additionally, you must get ready:
- vibration machine;
- crusher;
- molds for expanded clay concrete;
- cart;
- bucket;
- shovel.
By hand, boards or sheets of galvanized metal are used to create the molds. Additionally, prefabricated forms are available for purchase; these are produced in the same factories as expanded clay concrete blocks.
Step-by-step creation process
Once all of the supplies and equipment are prepared, you can start constructing stone. This procedure can be done in two ways: with an apparatus that vibrates and with homemade tools.
With improvised means
The first step involves creating a mold in order to cast the material. Use metal sheets or wood boards for this.
Mark the necessary measurements first, then cut out the necessary pieces with metal scissors or a jigsaw if you’re working with wood.
The side L-shaped pieces can be removed with welding or nails, and steel angles can be used to join the workpiece elements together.
It is still preferable to use a thin sheet of metal for the base; it is nailed to the bottom of the molds, completing the workpiece. Then proceed as directed to make the blocks:
- Mix the solution. For small batches, the mixture is made in a trough or bucket, if the batch is large, then a concrete mixer is used.
- Casting. The finished mass is cast into pre-made molds. A little advice: if production takes place using improvised means, then it is better to make individual molds rather than a whole workpiece. This will make it easier to pour the mass. After pouring the mass, it is thoroughly compacted to allow excess air to escape. If air chambers are required, then glass bottles are used, which are lubricated with oil on the outside and placed upside down in the mixture.
- The blocks are left in the mold for several days. When the composition has set, it can be removed from the mold and sent for drying.
Outside drying occurs when the weather permits. Blocks should normally be dried at a minimum temperature of +15 degrees, and ideally +20 degrees. Both the drying room’s size and its level floor are important.
On a special machine
The process is more automated with this technology than with the previous one, which makes things go more quickly. Multiple phases of work:
- At the first stage, the forms are prepared and the solution is mixed in a concrete mixer. To do this, first pour water and detergent inside. Then expanded clay is poured in and everything is mixed. The next step is to add cement, and finally add sand. Mix the mass well for 3-5 minutes.
- The finished solution is poured into molds. They are pre-lubricated with machine oil and installed on a flat surface. The room where work takes place should not be too humid.
- To compact expanded clay, which will float to the surface due to its low weight, a special vibrating machine is used. The mold is installed in the equipment and the vibration function is turned on. While the equipment is working, the mass is well compacted.
- Drying. After just 1 day, the stone can be removed from the formwork and sent for drying. The product will take 2-3 days to dry.
The speed of this method is different from the previous one. Here, the machine will take care of everything in a matter of time, so a person does not need to compact the mass in the mold on their own.
Crucial! Investing in vibration equipment is advantageous if you intend to start production.
Possible difficulties and errors
Both novices and experts can make the following mistakes when making their own blocks out of expanded clay and concrete:
- It is not recommended to steam the mixture that has just been poured into the molds – this will lead to its cracking.
- If you still plan to treat the products with steam, then it is better to first remove them from the molds.
- You cannot dry the molded blocks under precipitation or direct sunlight.
- The solution must be prepared only in the prescribed ratio, observing the desired consistency.
Some builders neglect to tamp the mixture after it has been poured. If this isn’t done, the finished block will develop pores in its structure, which isn’t what you want for a structural material. The final stone will become less durable as a result of this.
Pros and cons of self-production
There are several benefits to creating blocks by hand:
- reducing the cost of building a house;
- the ability to independently regulate the composition of the stone;
- the ability to work with available tools;
- independent monitoring of the quality of materials;
- it is possible to implement blocks.
One of the drawbacks is how long the work takes; however, this can be minimized if you buy a specialized machine. Once more, the machine is highly expensive, but if you intend to start production, it will pay for itself.
What is the cost?
You must determine the cost of the finished stone in order to determine if it is worthwhile to begin producing expanded clay concrete yourself.
For instance, you could figure out how much it will cost to pour 100 liters of the final mixture into molds. At the Russian Federation’s average price:
- cement – 4.8 p. per kg;
- sand – 3.4 rubles. per kg;
- expanded clay – 1.4 r. per kg.
Based on the previously mentioned ratios, you will require 7.7 kg of cement, 23.1 kg of sand, and 61.5 kg of expanded clay for every 100 liters of mixture. Here, 7.7 litres of water are added. Recalculating shows that the price of 100 liters of mixture will be approximately 201 rubles. One hundred liters of the final mixture is sufficient to make roughly ten blocks.
As a result, 201 rubles will be needed for 10 blocks, and 20 rubles for 1 block. The price of electricity and transportation can be added here. One block will set you back about 25 rubles total.
Compared to buying the same material from a factory or store, which costs twice as much, this is much less expensive.
An enjoyable do-it-yourself project that lets you make sturdy, lightweight building materials customized to your specifications is making expanded clay concrete blocks at home. This article will walk you through all the necessary steps, including molding and curing the blocks and determining the proper ratios for expanded clay, cement, and sand. With easy-to-follow directions and helpful advice, you can create premium blocks suitable for a range of building tasks.
Useful video
You can watch the full process of creating your own expanded clay concrete blocks in this video:
One satisfying and economical way to improve your building projects is to make your own expanded clay concrete blocks. You can create high-quality blocks that satisfy your unique requirements by keeping to a methodical process and the proper ratios for the mixture. Expanded clay significantly increases the value of your building materials because of its insulating and lightweight qualities.
To guarantee the longevity and strength of the blocks, precise measurement and mixing of the ingredients are essential. To get the best results, don’t forget to use the specified amounts of cement, sand, water, and expanded clay. At first, the process might seem overwhelming, but with perseverance and close attention to detail, it can be handled and even enjoyed.
Remember the significance of appropriate curing. The blocks will not crack if they are allowed to dry slowly and evenly, and they will also reach their maximum strength. The time spent curing these blocks will pay off in the end, whether you use them for walls, foundations, or other constructions.
Not only can you make your own expanded clay concrete blocks at a lower cost, but you also have more control over the specifications and quality of the materials. You can customize your construction projects to meet your exact specifications by using this do-it-yourself method. With the appropriate direction and practice, you can confidently create strong and useful building blocks for your upcoming project.