The modern market exposes such conditions that nobody needs a simple traditional clean concrete, that is, it is not used anywhere. Thanks to the creation of a variety of additives that allow you to change the quality characteristics of concrete for the better, you can get completely new materials.
The business plan for the production of foam blocks involves the creation of a qualitatively new building material that meets modern consumer requirements. Of course, it is possible to improve the heat and sound insulating qualities of concrete by adding various waste from other industries, such as polystyrene, expanded clay, sawdust, wood, slags, mineral wool, and so on.
You can organize a factory for the production of foam blocks using these mixing options. This will allow you to get high quality blocks that do not depend on external weather conditions, as well as optimizing the construction process.
Main characteristics
Distinctive features of such concrete are resistance to moisture, heat and frost. However, not everyone will be able to successfully combine among themselves two diverse enterprises, for example, a cement plant and a sawmill, as this entails significant material costs. This can be considered one more strong evidence in favor of drawing up and using a business plan for the production of foam blocks.
Manufacturing process
Foam blocks are made of foam concrete and aerated concrete. This material is obtained by adding certain substances to the main cement mortar. Obtaining aerated concrete involves the introduction into the mixture of components that lead to the formation of gas during the ongoing chemical reaction. Usually, aluminum powder is used for this process, which reacts with the excretion products during the hydration of the cement slurry.
Considering the chemical side of the process, we can talk about the evolution of hydrogen, which forms pores of various sizes in the solution. If we draw an analogy with everyday life, then we can talk about adding soda to the dough and the process that follows. Cement eventually begins to increase in volume, after which it hardens and porous concrete is obtained.
The production of the foam block is carried out in accordance with the technology, which involves the introduction of a special component in the form of foam into the cement mixture. There are a huge number of bubbles in the foam, which are evenly distributed over it during mixing with the solution. After the solidification of the mass, a porous effect is seen, as is the case with aerated concrete.
Modern construction involves the active use of both types of concrete. For example, aerated concrete can be used in the construction of load-bearing walls, and foam concrete, less durable and cheaper, for the rest of the walls. It turns out that a business plan for such production should involve the use of these two types of material.
The advantages of foam concrete
Foam blocks have a number of advantages. They are characterized by a high degree of sound insulation, easy to process, and do not allow air to pass through. If you decide to open a factory for the production of foam blocks, then you will need to purchase certain equipment that is designed to produce blocks of foam concrete. The choice of one or another set of devices depends on the method of production.
There are currently several options. Cutting production technology can be used when the mold is cut into pieces of predetermined sizes. Foam blocks are also obtained by formwork. The mixture is poured into a wooden formwork, and after the mixture has hardened, it is removed.
Production methods
Speaking about the first method, it can be noted that it is suitable for cutting aerated concrete. So you can get individual foam blocks of certain parameters. Cutting is done with a wire string. The foam block factory assumes the presence of a special cutting complex with a minimum size, which includes several cutting machines, a control panel and rails. This technology allows you to get maximum accuracy. For example, with a block size of 60 * 20 * 30, the cutting process takes about 10-15 minutes.
The machine for the production of foam blocks can be equipped with a gripping device, which is designed to accelerate the transportation of the blocks obtained in the workshop, crosshead for ease of removal of molds and more. All of the listed equipment can cost around a million rubles. With a great demand for the production of foam blocks, such equipment will pay off very quickly. To purchase it, you need to draw up a business plan that will take into account all the features of your plant.
Alternative option
It is possible to make a foam block at home. This is done using special equipment that is designed to produce this material. What is needed for the production of foam blocks? You will need a production line equipped with modern reliable equipment. The minimum set consists of a foam generator, concrete mixer and the molds into which mortar is to be poured. Such equipment can be purchased in kit or separately. You can buy a ready-made machine for the production of foam blocks, but sometimes it needs serious revision.
Advantages
The foam block is good for its cheapness. It is much more accessible than such types of building materials as wood, ceramic and silicate brick, expanded clay concrete blocks. However, a cheap foam block is not a bad material. In many European countries it is in high demand. The cost of foam blocks directly depends on their size. The blocks are thicker and larger, the higher their cost. If we consider the average price of a cubic meter, then we can talk about the amount of three thousand rubles.
The sizes and cost in this case can have completely different values. These parameters are dependent on production technology. The most common size of foam blocks is 600 * 300 * 200 millimeters, however, their width and thickness vary, and the length always remains fixed. Each of these points should be included in the business plan for the production of foam blocks.
The use of foam blocks of certain sizes in the construction depends on their functional purpose. If with their help the wall is laid out, then here you can use larger blocks. Internal partitions should be thinner. The field of application of the material, as well as its strength, depends on the thickness. If the size of the foam block does not allow it to withstand a compression load of more than 350 kilograms per cubic meter, then they can be used only as a material for building insulation, but not for load-bearing walls.
Expenses
Of course, the cost of opening an enterprise will depend on its capacity, that is, on the volume of material produced. If the output per day will reach 10-30 cubic meters, then you will need to invest 30-85 thousand dollars. In addition, the business plan for the production of foam blocks involves the purchase of additional equipment in the form of a compressor, a foam generator, as well as a peristaltic pump.
You will need to purchase special forms for concrete blocks of different volumes.A plant with a capacity of 10 cubic meters will require the acquisition of ten forms if one cubic meter of mixture is placed in each of them. Material costs for consumables are not so great, about 520-550 rubles for each cubic meter of foam concrete. So, now you know how much the equipment for the production of foam blocks costs.
Expected profit
Profit calculation should start with how much you can get for each cubic meter of foam blocks. The gross profit in this case is 2460 rubles. With a plant capacity of 10 cubic meters per day, you can count on 665,000 rubles per month.
From this sum it is required to take away payment of utility bills, rent, wages of workers. Together, all of these payments can reach 70% of gross profit. It turns out that the net profit in this case is at the level of 200-220 thousand rubles per month.
findings
If we talk about payback, provided that you bought all the equipment in installments, all the invested funds can be recouped in six months. When working at maximum equipment power, we can talk about the possibility of paying off in three to four months. It is worth acquiring exactly the most powerful equipment, as it will quickly pay for the entire production. It costs 2.5 times more, and produces five times more products.
