Activities preceding the sale of aerated concrete blocks. Business plan for the creation of aerated concrete production in the SEZ. Download example. Raw materials for the production of aerated concrete blocks

Activities preceding the sale of aerated concrete blocks. Business plan for the creation of aerated concrete production in the SEZ. Download example. Raw materials for the production of aerated concrete blocks

17.01.2022 Preparations

Staff
Sales
Taxation system
Permissions to open

How to organize a mini-production of aerated concrete in the current realities, and is it even worth climbing into this niche in the current competition, because a small enterprise will not be able to “survive” at the same prices for its products as the flagships of this niche, and a large one requires huge investments. Let's try to understand this issue.

How to start an aerated concrete business

To organize a business, you will need to rent a room. Its area, of course, depends on the scale of production, and it can vary from 70 sq. m. up to 600 sq. m. m. If the average cost of 1 square. m. per month is about 100 rubles in Russia, then the cost of rent will be from 7 thousand rubles. up to 60 thousand rubles A warehouse for storing aerated concrete is optional, as it is not whimsical and can be stored on the street.

What equipment to choose for the production of aerated concrete

You can purchase equipment for the production of aerated concrete yourself, or you can contact companies that will offer you ready-made lines plus training in production technology. The equipment includes: molds where aerated concrete is poured, an electronic water dispenser, a dispenser unit for bulk materials, a mass cutting device, an activator mixer and a slurry mixer. The performance of various ready-made lines can be different from 10 to 150 cubic meters. m per day. So their cost will be different, about 90 thousand rubles. and higher.

Raw materials used in the production of aerated concrete

One of the main issues in the production of aerated concrete is raw materials and their suppliers. The components in the manufacture are:

water, in the amount - 250-300 liters per 1 m3 of aerated concrete, temperature 40-60 gr.
Portland cement, in the amount - 260-320 kg per 1 m3 of aerated concrete.
fillers, in the amount of 250-350 kg per 1 m3 of aerated concrete, river or quarry sand can be used as it,
curing accelerator,
caustic soda
blowing agent, in the amount of 0.5-0.7 kg per 1 m3 of aerated concrete, it is aluminum powder.

Your task is to find profitable suppliers of raw materials in your area.

Manufacturing technology of aerated concrete blocks

The production of aerated concrete blocks includes the following technological algorithm:

form preparation,
preparation of aerated concrete mortar,
array filling,
cutting aerated concrete massif,
heat treatment,
disassembly of the array into separate blocks.

Staff

Not only the area of the required premises and the volume of raw materials, but also the number of jobs depends on the volume of production. With minimal volumes, you can do without hiring workers, the entrepreneur himself can handle it, but if you want to produce on a larger scale, you can’t do without hiring staff (from 2 to 10 workers). You should think about a two-shift work day. As for wages, it is equal to 100-200 rubles per 1 cubic meter. m. of manufactured products. This is somewhere around 20-30 thousand rubles. per month.

Sales

After the production of products, the question of its implementation arises. You can sell finished products to construction companies, private developers, and there are individual customers. It is only necessary to advertise your production: in newspapers, at construction markets, when leaving the city, near cottage settlements under construction, etc.

How much can you earn in the manufacture of aerated concrete blocks

What profit can the production of aerated concrete bring? Let's give brief economic indicators.

The cost of 1 cu. meters of aerated concrete will be about 1500 rubles. It consists of the cost of cement (250 kg - 1000 rubles), sand (300 kg - 180 rubles), aluminum powder and chemical additives (150 rubles), wages and overheads (150 rubles). In Russia, aerated concrete sold for at least 2500 rubles. for 1 cubic meter. Accordingly, your minimum profit will be 1000 rubles. and more. The advantage of this business is that it does not require large working capital, since it can take no more than 2-3 days from the time of purchase of raw materials to the sale of finished products.

How much money do you need to invest to start a business

The cost of creating a production facility for the production of aerated concrete will amount to 30,000-85,000 rubles, depending on the capacity of the produced concrete, (capacity 12 - 50 cubic meters per shift). The cost of molds for the production of blocks is 30,000-40,000 rubles (1 cubic meter of mixture is poured into 1 mold).

Total: 60,000-125,000 rubles.
You will also need consumables (per 1 cubic meter)
Powder aluminum, 500 gr. 105 rub. for 1 kg.
Sand 300-350 rubles. for 1 cu. meter (1.3 tons).
Cement 100 kg. 380 rub.

The cost of producing aerated concrete blocks is insignificant: 520 rubles. for 1 cu. m. The profitability of the production of aerated concrete in all regions is high.

Which OKVED to indicate when registering a business for the production of aerated concrete

OKVED 26.61 - production of concrete products for use in construction; OKVED 23.69 - production of other products from plaster, concrete or cement. If you plan to wholesale aerated concrete, then you must specify OKVED 46.73.6 - wholesale of other building materials and products.

What documents are needed to open

It is necessary to register a business entity: most often it is an individual entrepreneur. If it is planned to sell materials through large companies, then it is recommended to register a limited liability company. Prepared documents are submitted to public authorities or to multifunctional public service centers (MFCs). It is also necessary to register with the Pension Fund, Social and Medical Insurance Fund. For settlements with legal entities, you need to open a bank account.

Taxation system

To conduct this business, it is better to choose a simplified taxation system, the simplified tax system - “Income minus expenses”, since in the production of blocks there is a constant cost for raw materials. The only requirement in this system of taxation is proof of expenses. The tax will be from 5% to 15%.

Permissions to open

To open the production of aerated concrete, a license to conduct activities is not required. But you need to get permission from Rospotrebnadzor. To do this, you must provide the following documents:

constituent and registration documents;
premises lease agreement;
copies of documents for equipment.

In addition, it is necessary to obtain permission from the fire department, the sanitary-epidemiological service, environmentalists. The lease agreement for the premises must be drawn up for a long period.

Now the technology for the production of aerated concrete blocks is of interest to many people, especially those who plan to build a country house or open their own business. This material is quite durable, and also has good heat and noise insulation properties.

In this article, we will talk about the types of aerated concrete blocks, and what will be required to implement a business for their production.

business concept

The scope of aerated concrete blocks in construction is quite wide. This material is resistant to different climatic conditions, it is used with caution only in the northern cold regions. It has high strength, thermal insulation properties.

Business clients are different organizations:

construction shops, specialized markets and bases of building materials;
companies involved in the construction of various facilities;
individuals for use in individual buildings.

Most of the client base falls on individuals who purchase material for the construction of residential buildings, summer cottages. Blocks are often used for the construction of low-rise residential buildings and office buildings.

Types of aerated concrete blocks

Aerated concrete block is a type of artificial stone based on cement and sand. Manufactured using gas generation technology. One of the types of cellular concrete. Blocks can be classified according to different criteria.

Depending on the conditions of solidification of the product, to complete the production, the following are distinguished:

autoclave - hardening occurs in special ovens under the action of steam;
non-autoclave - a natural environment or an electric heating environment is used.

According to the main binder component:

cement - in the composition of up to 50% Portland cement;
calcareous - contain up to 50% boiled lime;
slag - the share of slag with lime or gypsum is up to 50%;
ash - contain up to 50% of highly basic ash;
mixed - include ash, slag and Portland cement in concentrations up to 50%.

By type of silica component:

using secondary products of other industries;
using natural sand.

Prices for aerated concrete blocks from leading manufacturers whose products have been certified:

"Yutong" - price for 1 pc. is 195 rubles. (1 m³ costs 4150 rubles);
Bonolit D-300 - price for 1 pc. - 126 rubles. (1 m³ costs 3400 rubles);
Bonolit D-500 - 1 pc. costs 110 rubles. (1m³ costs 3000 rubles).

The price is acceptable for buyers with a limited budget.

Stable demand for aerated concrete blocks is explained by low costs and high quality of the material.

What is required for implementation?

To create your own mini-plant for the production of aerated concrete blocks, you will need knowledge of the manufacturing technology of this building material. In general, it includes several stages:

Mixing components. The basic components of aerated concrete are quartz sand and cement. You can mix the raw materials manually or using a special installation. To achieve a certain effect, additional components are included in the composition.
Adding slurry and aluminum powder to start the gassing process. Connecting the components takes about 15 minutes.
Moving the solution into special uniform containers for 3-4 hours. After that, the mass is cut into blocks with a special device.
Maturing of blocks within 14-18 hours.
Autoclaving in an oven at 12 kg/sq. cm and a temperature of 190˚.
If there is no autoclave oven, the blocks mature naturally within 4-6 days.
Final ripening in a ventilated room for 30 days. Further transportation to the construction site is carried out in a shrink film on wooden pallets.

Autoclaving makes the stone stronger and more stable, which affects its price. The shrinkage of the material processed in the furnace is much less.

Mini plant for the production of aerated concrete blocks

For the manufacture of aerated concrete blocks, special equipment is required:

Stationary discharge means an installation in which the aerated concrete mixer moves on rails along fixed steel molds. The line is equipped with a special sieve for screening sand from large particles. The productivity of such equipment is 20-60 cubic meters. m per day, which entails the need to maintain facilities for the storage of raw materials and finished products. Also, 3-4 workers will be required for maintenance. The cost of such an installation starts from 1,250,000 rubles.
mini-line, the operation of which is ensured by the movement of the aerated concrete mixer using a wheelbase. Productivity is 10-15 cubic meters. m per day. A distinctive feature is the ability to ensure the operation of equipment without a stable source of energy, using only a generator. The initial cost of the mini-line is 380,000 rubles.
assembly line production. High performance (up to 100 cubic meters) of such an installation should be provided with an area of 600 square meters. m. The cost of equipment is higher than in the case of other installations and is more than 2,000,000 rubles.
installations for personal use. It is used for the manufacture of aerated concrete at the immediate construction site. The cost is close to the price of mini-lines. No special conditions are required to use the equipment.

The operation of any installation implies the same manufacturing process. You can vary the percentage and composition of the components. Depending on the scale of production, it is necessary to purchase raw materials and organize conditions for storing the finished stone.

Step by step start instructions

Business registration. The priority forms are individual entrepreneurs and LLCs. It is also necessary to make a transition to a simplified taxation system.
Search for premises for placement of equipment, materials and finished blocks. You will also need space for workers. It is advisable to choose a warehouse in an industrial area. The area depends on the planned scale of production.
Purchase of equipment.
Purchase of raw materials for production. It is carried out in time together with the next stage.
Installation of equipment. It is worth making sure that the line is ready for launch and is working properly.
Search and briefing of personnel. It takes 3-4 people to service a small production.
Start of production. Production of a trial batch of blocks, troubleshooting if necessary. Composition adjustment. With stable operation of the equipment - production in accordance with the possible capacity.
Creation of sales channels and search for customers. Includes the creation of a price list and the formation of a commercial offer, as well as the implementation of an advertising campaign.
Formation of a stock of finished products.

A feature of the building blocks business is its seasonality. Products are most in demand in late spring - early summer. By this time, it is necessary to create a sufficient inventory for which it is necessary to provide storage conditions.

Financial calculations

The production of aerated concrete blocks is one of the available types of business, the costs of which are quite variable. The cost of equipment is selected based on the available budget, and raw materials do not require high costs.

Start-up capital

In this table, the calculation of the amount to start is made for the average production scale. More expensive equipment and more raw materials will ultimately generate more profit and shorten the payback period. For smaller production volumes, the cost of equipment starts from 85,000 rubles. The cost of renting and maintaining the premises may also vary.

Monthly expenses

Most of the costs are for materials and electricity. You can reduce costs by choosing a profitable supplier, reducing workers or optimizing their work. You should also pay attention to the logistical validity of transport costs and control of resource consumption.

How much can you earn

In the production of 15 cubic meters. m per day and 22 working days per month and the price per 1 cu. m. of aerated concrete 3,000 rubles. we get: 15 * 22 * 3000 = 990,000 rubles. per month of work. Thus, the profit for the month will be: 990,000 - 747,000 \u003d 243,000 rubles. The cost of starting a business will pay off in 6 months with an optimistic calculation option. The actual period can be extended up to 1 year in case of sales problems, insufficient production efficiency and delivery delays. Advertising also plays a significant role, which should work effectively.

Business risks and cons

The production of aerated concrete blocks is a profitable business, but it also has its drawbacks:

high competition. The relative ease of starting production and a small list of necessary materials made the market saturated. To fight with competitors should improve the quality of their own products;
seasonality. A stable income in this industry is almost impossible. During the period of consumer activity, it is necessary to ensure a stable supply of products. In this case, a lost day can cost a month's earnings;
lack of a permanent client base. Most clients make only one order during the active construction period. Relatively constant demand is observed only among construction companies.

The production of aerated concrete blocks requires knowledge of the technical side and the availability of special equipment. With a competent approach to the implementation of the business, the owner will quickly pay back the invested funds, despite the fact that the amount of initial investment is quite large.

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What is aerated concrete, its technical characteristics

Aerated concrete is one of the varieties of cellular concrete. The building material is an artificial stone with a porous structure. The pores are evenly distributed throughout the volume and have a rounded or oval shape. Their diameter does not exceed 3 mm.

According to the manufacturing technology, aerated concrete is classified into 2 types:

autoclave;
non-autoclave.

The material is used in the construction of residential and non-residential facilities. Most often, walls and partitions are built from it. Reinforced aerated concrete is used for the manufacture of floors.

The composition of the material includes:

cement;
sand;
lime;
gypsum;
finely dispersed metallic aluminum;
ash;
slag.

Consider the technical characteristics of aerated concrete:

The length of the products is 62.5 cm, the height is 25 cm. The width can be different - from 10 to 40 cm.
Due to the porous structure, the material has a low weight - the mass of 1 m2 is 600–800 kg.
The thermal conductivity of aerated concrete differs depending on the brand and ranges from 0.048–0.28 W.
Material shrinkage - 0.5 mm / 1m.
Frost resistance is 2 times higher than that of brick - more than 70 cycles.
Aerated concrete is not subject to combustion.

Advantages and disadvantages of aerated concrete blocks

Aerated concrete is a relatively “young” material; it has been used in the construction market for about 80 years. However, it has already managed to gain popularity due to its advantages:

high environmental friendliness;
fire resistance;
low density and, as a result, low weight;
ease of processing;
high speed of erection of structures;
excellent thermal insulation properties;
low cost.

Reference. Aerated concrete is a breathable material. The coefficient of air permeability of products from it is similar to structures made of wood.

Aerated concrete as a building material is not without drawbacks. It is fragile - blocks can break during transportation or laying. Another disadvantage is the high water absorption capacity. Walls built of aerated concrete will have to be protected from moisture. Structures made of this material quickly heat up and cool down. Lime, which is part of the composition, has a destructive effect on metal parts that are used in construction.

Attention! Another minus of aerated concrete is manifested in the interior decoration. For this purpose, manufacturers advise using gypsum-based plaster, which is applied to the mounting grid. Otherwise, the surface of the walls cracks at the junction of the blocks.

Types and technology of material production

Aerated concrete is produced in two ways - autoclaved and non-autoclaved. In the first case, the blocks are placed in a special oven, where they quickly harden at high temperatures. In the second case, the products are dried naturally for several days. In terms of quality characteristics, gas blocks obtained by a non-autoclave method are inferior to products that have undergone heat treatment in a furnace.

The technological process includes the following steps:

preparation of raw materials;
preparation of the mixture in a dosing-mixing machine;
pouring the mass into molds;
cutting blocks into products of the desired size;
autoclaving;
packaging of finished aerated concrete blocks.

First, raw materials - Portland cement, sand slurry, lime, water and binders are loaded into the batching and mixing department. Components in the right proportion are mixed and turned into a homogeneous mass.

Further, the mass enters the mold, where intensive gas formation occurs as a result of a chemical reaction. When the process of active gas evolution stops, the molds are kept at room temperature or in a heat chamber until the strength of the raw material reaches 0.04–0.12 MPa. Then the molded products go to the cutting complex. Here, with the help of special steel threads or strings, the plate is cut lengthwise and across into products of the desired size.

After cutting, the blocks are transported on autoclave trolleys to the oven. After its full loading, the products are processed at a temperature of 190 degrees and a pressure of about 12 atmospheres. A certain humidity regime is maintained inside the oven. Finished products are unloaded from the autoclave after a gradual decrease in pressure. Aerated concrete blocks arrive at the packaging department and are sent to the finished product warehouse.

In the production of aerated concrete by a non-autoclave method, the mixture in the molds hardens naturally, without the use of ovens. To improve the properties of the material obtained by this method, modifying additives must be included in the composition of the mixture.

Business benefits and possible risks

The production of aerated concrete as a business has a lot of advantages. For instance:

the project pays off quickly;
products are in demand;
you can start with a relatively small amount of investment - from 1,500,000 rubles;
high yield and profitability.

The main disadvantage of business is the high level of competition. In Russia, the production of aerated concrete has long been debugged, many companies are successfully developing in this direction. Those who plan to open a mini-enterprise for the production of gas blocks should take into account the possible risks of the project:

an increase in the cost of raw materials, which will entail an increase in the cost of products;
increase in rent and the cost of utilities;
development of new building materials, the qualitative characteristics of which will surpass the properties of aerated concrete;
emergence of new competitors.

Market analysis

In most European countries, the share of building walls of residential and non-residential buildings from cellular concrete is 30-40%. In Russia, interest in this building material is gradually growing, but has not yet reached such values. In our country, housing construction from aerated concrete is stimulated by such factors:

the growing need of the population for housing, especially in settlements located near metropolitan areas;
active development of low-rise construction in rural areas;
tightening requirements for thermal protection of buildings.

An additional incentive is the affordable cost of aerated concrete - it is cheaper to build from it than from brick or wood. In addition, the construction of buildings from cellular concrete is many times faster. For example, a team will build a residential building with an area of 100 m2 in a few days.

All these factors affect the increase in demand for the product. The aerated concrete market has been developing rapidly in recent years. Marketers predict further growth in demand for cellular concrete due to a reduction in the volume of brick construction.

Reference. Among the CIS countries, Belarus is the leader in the use of aerated concrete. In this country, almost 40% of residential buildings are built from this material.

Step by step business organization

The organizational plan includes several stages of work. The first is the registration of the type of activity, its legalization. The next steps of the entrepreneur are the search for a production facility, the purchase of equipment, installation and debugging, the search for suppliers of raw materials and workers.

Company registration

If you plan to open a small production workshop, you can register an individual entrepreneur, not an LLC. As a taxation system, it is better to choose the simplified tax system with a rate of 15% of profits (revenues minus expenses), since large expenses are expected for the purchase of raw materials. If an entrepreneur wants to continue to cooperate with large organizations, you need to open an LLC with one founder and write an application for the application of the simplified tax system.

In addition to the constituent documents, you will need permissions:

from Rospotrebnadzor;
fire inspection;

When registering an individual entrepreneur or LLC, you will have to select OKVED codes that allow you to conduct activities related to the production of products from concrete, cement and artificial stone, for example:

23.61;
23.61.1;
23.61.2.;
23.69.

room

For the production of aerated concrete, you will need a room, part of the area of \u200b\u200bwhich is allocated for equipment, and the remaining space is used to store finished blocks. The workshop area is determined depending on the planned volume of products, but not less than 100 m2.

Workshop Requirements:

perfect condition of the wiring;
availability of heating and plumbing;
good entrance;
it is desirable to have a spacious area near the premises for the convenience of loading and unloading.

To purchase a production line, you should contact a specialized company. It is possible to purchase all units separately. Necessary equipment:

dispenser. Measures the right amount of components according to the recipe. The price ranges from 120,000–180,000 rubles.
Mixer. Used to mix ingredients. The cost is 90,000–100,000.
Cutting complex. Cuts the layer into blocks of the desired size - 400,000.
Water dispenser. Price - 25,000.
Steam generator. It is used for processing gas blocks. The unit will cost 45,000-50,000 rubles.
Vibrating sieve. Used for sifting sand. Price - 40,000–45,000.

In addition to production equipment, you will have to purchase pallets for storing and transporting finished products. The total cost of the production line will be from 700,000 to 900,000 rubles.

One of the main tasks of an aerated concrete business owner is to find reliable suppliers of raw materials who sell products at a bargain price. Each manufacturer has its own recipe for the preparation of porous concrete, but the composition of the building material always includes the following ingredients:

Water. For 1 m3 of aerated concrete, 250–300 liters of water of medium hardness, heated to a temperature of 40–60 degrees, are consumed.
Portland cement. Consumption - 260–320 kg/m3. For the preparation of aerated concrete, grades M400DO and M500DO are used.
Finely dispersed filler - quartz sand.
Aluminum powder or suspension. Plays the role of gas generator. Consumption - 500-700 g / m3 of aerated concrete.
Additives (1–3 kg/m3). Chemicals that speed up reactions.
Other components are used motor oil, vegetable oil waste, emulsols. Used to lubricate the mold.

Formation of staff

The purchase of automated high-tech equipment relieves the entrepreneur of the need to hire a large number of employees. At first, while the enterprise will not operate at full capacity, two workers and one technologist are enough. When production volumes increase, it is possible to organize a shift work schedule and expand the staff. Management will be taken over by the business owner, and accounting can be outsourced.

Wholesale buyers of aerated concrete blocks prefer to cooperate with companies that provide delivery services for finished products. In this regard, the entrepreneur needs to decide how to satisfy this need. If the budget allows, it is worth buying your own transport for transporting goods. Otherwise, you will have to rent cars, but these are additional costs.

Since it will take a lot of money to buy several trucks, you can do without your own transport until the enterprise reaches the break-even point. When the investment pays off, it is worth getting trucks.

Search for sales channels for aerated concrete

The most difficult stage of organizing a business is the search for distribution channels for gas blocks. In order for production to work at full capacity, you need to constantly sell products. Finding buyers is not so easy - most developers are already cooperating with other suppliers of building materials.

post ads at the entrance to cottage settlements under construction, at the exit from the city;
advertise in newspapers;
place advertisements for the sale of aerated concrete on free and paid sites on the Internet;
communicate directly with developers and offer them products at a bargain price;
create a website and promote it.

The peculiarity of business is seasonality. Demand for building materials increases during the warm season. This factor must be taken into account when organizing. Well, if the start of production will be at the end of February - the beginning of March. Then the entrepreneur will have enough time to develop regular customers.

Attention! If there are already similar enterprises in the region that produce aerated concrete, the new company should stand out against their background in terms of product quality, delivery speed, and cost of products.

Financial calculations

The business plan contains information about the amount of investment, current expenses and expected income. By comparing these data, you can find out what is the profitability of the project and how soon the investment will pay off.

Project investment and maintenance costs

The volume of investments for the opening of production:

execution of constituent and permissive documentation - 10,000;
purchase of equipment - 800,000;
payment for the rent of the workshop for 6 months in advance - 120,000;
preparation of the premises for operation - 50,000;
expenses for the first batch of raw materials - 750,000;
advertising - 20,000.

Total: 1,750,000 rubles.

Every month, the business owner spends money to maintain the project. Current expenses include:

workshop rent - 20,000;
utility bills - 10,000;
salary - 100,000;
payment for the services of an accountant - 6,000;
raw materials - 1,300,000;
depreciation, maintenance of the production line - 10,000;
advertising - 5,000;
tax - 15% of the difference between dirty income and expenses.

Total: 1,431,000 plus taxes.

Income and profit calculation, project efficiency

For 1 shift, the company produces 36 m3 of aerated concrete. The cost of 1 m3 is 1600 rubles, and the selling price is 3500 rubles. Let's do the calculations:

The volume of production for 23 working shifts is 23x36 m3 = 828 m3.
The company's monthly revenue is 828 m3x3500 rubles = 2,898,000 rubles.

Let us determine the net profit of the enterprise by subtracting current expenses and tax deductions from the amount of revenue for the month: 2,898,000–1,431,000 \u003d 1,467,000–220,050 (15% tax) \u003d 1,210,950 rubles.

Calculations show that even when working in one shift, the company earns more than 1 million rubles of net profit per month. It is important to understand that such results can be achieved no earlier than in 3-5 months. This time is necessary to find regular customers. As soon as the workshop reaches the planned sales level of 828 m3 of aerated concrete per month, it will be possible to expand the staff and switch to shift work in order to produce more blocks.

The payback period of the project depends on many factors - sales volume, production line capacity, the amount of initial investment. On average, it is 3-6 months. Business profitability - 41.78%, this indicator is calculated by the ratio of net profit to gross, multiplied by 100 - 1,210,950/2,898,000x100% = 41.78%.

Building a business in the production of aerated concrete blocks is not an idea for beginners. To implement such a project, you will need not only a large amount of money, but also skillful marketing, because the success of the event depends on the volume of products sold. In a highly competitive environment, it is very difficult to find regular buyers for large batches of aerated concrete. For the successful development of the project, it is recommended to hire a competent marketer.

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ADVANTAGES OF AERATED CONCRETE

Aerated concrete blocks are a modern building material, a kind of cellular concrete. Its widespread production and use is due to the inherent advantages of aerated concrete.

The composition of aerated concrete blocks

aerated concrete is a mineral stone of artificial origin with a porous structure. Its peculiarity is that air bubbles of spherical shape with dimensions of 1-3 mm are evenly distributed throughout the volume.

The material consists of a mixture of cement, lime, sand and water. In the production, special gas generators are used, which, entering into a chemical reaction, emit hydrogen, which “foams” the mixture, as a result of which its volume increases, and the structure becomes porous. Foam blocks differ from aerated concrete in the method of production, composition, and characteristics.

The aerated concrete block becomes porous due to chemical reactions, foam blocks - as a result of mechanical mixing of a mixture of sand, water, cement and prepared foam.

The standard cycle for the production of aerated concrete blocks begins with the creation of a basic composition. To do this, the dry components are mixed with water, and then the solution is poured into molds. After foaming and pre-setting, the blanks are removed from the mold and cut. The final drying of the material takes place in special chambers, where the mass is treated with steam in an autoclave under high pressure. This allows the material to acquire such qualities as: environmental friendliness, durability, fire resistance, high strength, good sound insulation, thermal insulation, frost resistance, high vapor permeability. Depending on the final cycle, aerated concrete is divided into “non-autoclave” and “autoclave”, respectively.

Foam concrete and aerated concrete are easy to confuse, however, these two materials have significant differences:

1. In the composition of foam concrete, instead of more expensive quartz sand, production waste is used. This reduces the cost of construction but degrades performance.

2. Drying of foam concrete blocks takes place in the open air, which affects the performance of the material.

3. Aerated concrete products have better thermal insulation characteristics than foam concrete products.

4. Unlike foam concrete, aerated concrete blocks do not shrink during operation.

5. In aerated concrete, small pores are evenly distributed and have almost the same size, foam concrete pores are much larger.

An easy way to distinguish aerated concrete blocks from foam concrete blocks is to pay attention to the color. Aerated concrete products are always white, foam concrete is more gray and dark.

Advantages of aerated concrete blocks

Aerated concrete is not accidentally used as a building material around the world. Its production is mastered in 50 countries. The advantages of aerated concrete structures are due to good performance characteristics.

The durability of the material is compared with brick structures, the service life of blocks can reach 100 years or more.
The strength of gas blocks is due to the optimal density ratio in the porous structure.
The environmental friendliness of the material is achieved due to the absence of toxic components in the composition. The blocks are made from traditional raw materials that do not emit harmful substances clean.
Compared to ordinary concrete, aerated concrete is not radioactive, since it does not contain crushed granite and mica (natural sources of thorium and uranium).
The ability of a material saturated with water to withstand alternating cycles of freezing and thawing is called frost resistance. Due to the capillary-porous structure of aerated concrete, its frost resistance is relatively higher than other similar materials.
Aerated concrete is a non-combustible material, it does not burn itself and does not support the spread of fire.
The energy efficiency of aerated concrete is associated with its good performance in terms of heat resistance. Many pores in the structure of the material are excellent cold insulators. Therefore, buildings with external walls made of aerated concrete blocks keep cool in summer and warm in winter. Thanks to the same property, the material has excellent soundproofing properties.
Thanks to a special production method, all aerated concrete structures have consistently accurate dimensions, which allows you not to additionally level the walls with plaster, but only to apply a thin putty.

Another valuable advantage is the possibility of simple processing of the material. Aerated concrete blocks are easy to cut with hand tools.

Comparison of foam concrete and aerated concrete - which is better
The table compares the main parameters that determine the properties of gas blocks and foam blocks

Parameter	foam concrete	aerated concrete
Pore former	saponified wood resin (moderately hazardous)	powdered aluminum
Manufacturing technology	Block casting	block cutting
Variety of elements	Less	More
Compressive strength, for grade D500	IN 1	At 2.5
Size Accuracy	There are errors	Minimum error
Frost resistance, cycles
Thermal conductivity, W/M*k	0.08 (thermal insulation) - 0.36 (structural)	0.1 (thermal insulation) - 0.14 (structural
Appearance	satisfactory	good
Shrinkage, mm/m.p.	2-3	0,5
Possibility of masonry reinforcement	No	There is
Average thickness of a single-layer wall, m	0,63	0,4

Investment projects for the production of aerated concrete are economically highly effective, and are a promising direction for investment in the Russian building materials industry

Normative documents

GOST 31359-2007 Autoclaved cellular concrete. Specifications

Federal Law No. 261-FZ"On energy saving and on improving energy efficiency and on amending certain legislative acts of the Russian Federation" dated November 23, 2009 ...

Order of the Ministry of Economic Development of March 23, 2006 N 75 On approval of the forms of business plans submitted for the conclusion (change) of agreements on the conduct of industrial and production (technological and innovative) activities, criteria for selecting banks and other credit organizations for preparing an opinion on business plans, criteria for evaluating business plans conducted by an expert council on technology-innovative special economic zones (as amended by the Order of the Ministry of Economic Development of the Russian Federation of 04/05/2018 N 159) ...