People who first encountered such a complex procedure as the choice of equipment for the production of foam concrete are not always able to understand the terms that accompany this. Most sellers, making loud signs with the names of devices, can sell simple cassette forms with settings for creating material. Exactly the same devices with cassettes can always be seen in other ads. You should understand this issue, as the choice of equipment for the production of foam concrete, in more detail.
Key Concepts to Know
If you decide to open your own business, it is very important to understand the following terms:
- Foam concrete mortar is a substance that is obtained by mixing the ingredients: cement, foam and sand.
- By foam concrete is meant a material that has a porous structure. It is obtained using a procedure such as hardening a solution.
- Under the foam blocks are understood the materials in the manufacture of which foam concrete was used.
- Installation for the production of foam concrete - equipment that is necessary for a specific use.
- A production line is a complex of devices that are interconnected with each other and operate according to a specific technological process.
First of all, the equipment must create a solution
When choosing equipment for the production of foam concrete, it should be understood that it is necessary to create the appropriate solution. The production of blocks is already engaged in other equipment, which means cassette forms or a cutting machine. By putting all these devices together, you get a production line.
Basic devices specific to in-line equipment
In-line installation for the production of foam concrete includes the following devices:
- Equipment that is necessary to create foam concrete. The finished product is the material itself.
- The equipment that is required to create the blocks. Foam blocks are obtained as starting material.
So, what do you need to know in order to make the right choice in favor of a certain line for creating material?
Making the right and competent choice
On what, and most importantly, how is the creation of foam blocks? The production of foam concrete usually proceeds through the use of equipment in two ways: using a foam generator (the device needed to produce foam) and, accordingly, without it.
A machine for the production of foam concrete without the use of a foam generator works according to the following principle. Cement, sand, water, a foaming agent, and an acceleration additive are introduced into a special vertical mixer. After all this, an active “whipping” procedure takes place. The device itself reaches a speed of 1,500 (in one minute). However, this simplicity also has disadvantages.
The main disadvantages of the material
The material obtained through the use of such an installation is not of high quality. This is due to the fact that it is not possible to determine with high accuracy the necessary ratio in which the components for the production of foam concrete should be added. The mixing time will also affect a lot. In this regard, the likelihood of a marriage increases, since due to an error in the quality and quantity of the foaming agent, the whole batch can be spoiled.
In addition, due to the heterogeneity of mixing, the final material can be obtained with sufficiently large pores, which leads to its delamination. Thus, manufacturers will encounter a lot of difficulties during the sale of foam blocks made of such material.
A considerable impact can have not too high reliability of such equipment. Due to the fact that there is a high speed of rotation, the seal assemblies can be broken. And this, in turn, leads to the occurrence of fairly frequent interruptions in all work. And it should be noted that manufacturers who are trying to sell equipment talk about the need to purchase a compressor, as well as an expensive and capricious gerotor pump.
All the negative sides were removed
Equipment for the production of foam concrete with their own hands using a foam generator does not have such disadvantages. This apparatus provides that the preparation of foam is carried out in a separate device. Before filling the concrete mixer with the necessary material, it must be carefully checked.
It must fully comply with all requirements. Only in such a situation can high-quality material be obtained at the output. Such an indicator as density will depend on the amount of cement with sand. In this situation, it is possible to exclude the possibility of marriage.
In equipment of this type, in most cases, horizontally located shafts and screw mixing are also used. Due to the high efficiency of the “whipping” process, it is possible to obtain homogeneous concrete at the outlet. There should always be a compressor in the production line, since the displacement of the material must be done using compressed air.
In addition to the fact that the production line should have a pressure unit for the production of foam concrete, it is worth considering the purchase of devices with which you can get foam blocks.
What devices do you need to purchase to get the blocks?
There are two types of devices with which you can achieve what you want. We are talking about cassette forms in which injection technology is used, as well as equipment using cutting technology.
The cassette shape at first glance may seem too simple. However, all this is quite deceptive. What could be easier - uploaded, disassembled, sent to the customer.
However, you should be aware of some of the nuances when working with the installation. The limitations that are characteristic of the period of use of the forms do not meet the standards.
This is due to the constant effects of the mechanical type on the equipment. Deviations in the form of blocks can reach more than 5 mm. Therefore, the blocks that were produced through the use of cassette installations must be laid on the solution.
In order to ensure continuity of work, it is necessary to use two sets of forms. You will need to hire 12 employees. This is due to a lot of manual labor.
Characteristics of the cutting machine
The cutting complex has some advantages. If you use it, the number of staff is reduced by almost half. Manual labor excluded. The cost will be much lower than when using a large number of cassette forms. You can make blocks of quite impressive size. Such material is used by many construction organizations in connection with high quality.
Conclusion
Thus, based on all of the above, we can say that for the production of foam concrete and foam blocks, the most optimal equipment options will be: installation with a foam generator and a cutting complex.
