Description of technology
First of all, you need to know the specifics of producing concrete products. The production of cinder blocks is based on the method of vibration pressure of the material, as a result of which a product is formed with the required geometric parameters and specific density.
In practice, this is done using special equipment. Its work can be considered using the example of cinder block production, where the Vibromaster vibrating machine will be used as the main production unit.
- Preparation of the solution. To do this you will need cement (1), sand (8), water (0.5) and filler (3). The percentages relative to the total volume are indicated in parentheses.
- Next, the resulting mixture is gradually added to the working capacity of the machine. At this time, it operates in low vibration mode to fill all voids and distribute the solution evenly.
- After filling the container, the top cover of the device is closed, and a cinder block is formed in intense vibration mode.
- Using a lever mechanism, the product is removed from the machine and transferred to drying.
This is how production takes place. How to choose the best equipment for the production of cinder blocks?
Machine form
Machines for making cinder blocks vary in design complexity.
This can be a collapsible device made of wood or metal. It has different sizes depending on the number of blocks that will be produced at the same time. This design can be made with your own hands; bottles of the required diameter filled with water are used to produce voids. In this case, a vibropress is not used.
Another option is a vibrating machine, which consists of a mold located on a table or a special stand. This device is equipped with a motor and can be equipped with a lifting mechanism for removing finished products from the mold.
vibration machine
Wood or metal structures are used as a mold for making cinder blocks. The standard size is 390×190×190 mm, but you can choose the dimensions at your discretion.
Since slight shrinkage will occur during pressing, it is necessary that the height of the mold exceeds the height of the block being produced by 5 mm.
Advice ! When making a template from metal, you need to place the welding seams on the outside. This way, it will be easier to get the finished product.
Selection options
Most often, the initial capital for starting a building materials manufacturing business is small. Therefore, the main selection criterion is cost. It is worth noting right away that an effective vibrating machine for the production of cinder blocks will cost a lot. But its work and established sales market will quickly pay for the acquisition costs.
The main selection parameters are:
- The number of cinder blocks produced in one operation.
- Batch production time.
- Number of service personnel.
- Device power consumption
- Type of machine – stationary or mobile.
Based on this data, you can select the optimal device model. Depending on the area of application, several types of equipment are distinguished.
How to make a vibrating machine for cinder blocks with your own hands
Many people wonder whether a cinder block production machine should be vibrating. Here we can safely answer that, yes, the presence of a vibrating machine will allow us to make cinder blocks of the best quality, without voids inside. The drawing of a vibrating machine for cinder blocks in itself is not too difficult to master, and the main elements of a vibrating machine are:
Matrices for pouring the solution, which are mounted on top of the vibration installation. To make a matrix for a cinder block, you will need to take a steel sheet with a thickness of at least 0.2 mm. The metal sheet is cut into rectangles having the following dimensions: 390x190 mm. Their number is determined individually, depending on exactly how many cinder block matrices need to be made.
Typically, no more than three matrices are installed on one block vibrating machine. After welding the cut pieces of metal, it remains to provide voids inside the future matrices. For this purpose, you need to take a metal pipe 90 mm in diameter, and then cut it into 9 pieces, 190 mm long. To weld pipes to each other, a metal strip should be used.
At the next stage of manufacturing a vibrating machine for cinder blocks, you assemble the press yourself. There is no point in refusing to manufacture it, since using a press for a vibrating machine, it will be possible to exert the necessary pressure on the mixture poured into the matrix. To make a press for a vibrating machine, you will need to cut a rectangle out of metal exactly to the dimensions: 385x185 mm. Then, in the same way as the pipes are installed in the matrix, three even holes will need to be cut in a piece of metal.
Vibrating table assembly
The third stage in the manufacture of a vibrating machine for cinder blocks includes assembling the vibrating table. Here you can go in two ways: make a vibrating table, with eccentrics on the axes and a subframe, or significantly reduce the cost of the entire structure.
In this case, directly to the side of the tabletop, which would accommodate three matrices, you should screw fasteners for an electric motor with a power of at least 0.5 kW. Then a nut with an eccentric is attached to the motor shaft, which will create the necessary vibration while the motor is running.
It is very important to use a closed-type electric motor when manufacturing a vibration machine. If nothing else is at hand, then you should provide a special apron from a piece of metal that would completely cover the engine and prevent water and solution from getting inside it.
The final stage in the manufacture of a vibrating machine is the installation of the table top with the motor on the supports. To do this, you will need to weld a frame from a metal corner; at the bottom of it, if desired, you can easily attach wheels if you need to have a mobile vibrating machine for cinder blocks on hand.
For private use
If you need to purchase a vibrating machine for the production of cinder blocks and you need to build one low-rise building, then you should adhere to certain criteria. There are special models of equipment designed for the manufacture of one product.
They have low productivity and are not always convenient to use. But their affordable price more than compensates for these shortcomings. However, in this situation, you should be meticulous about the quality of the machine. Under repeated standard loads during operation, individual elements should not deform or break. It is desirable that the package includes several molds - for making hollow and filled cinder blocks. Changing the size of the product in such models is very rare.
Types of equipment
When opening a workshop for the production of cinder blocks, you will need:
- concrete mixer;
- vibrating sieve;
- wheelbarrow;
- racks;
- cinder block machine.
There are several types of machines on the market:
- mechanical with manual control;
- semi-automatic;
- fully automatic lines.
They can also be divided into three categories:
- portable;
- mobile;
- stationary.
Portable – mechanical machines with manual control. As a rule, in one cycle it is possible to produce 1 cinder block or 2 half-blocks. They are characterized by mobility, simplicity, low weight and cost:
- Block Master 2 (BM-2) is a portable machine with a productivity of 40 pieces/hour and a power of 0.25 kW. The cost of such a machine is from 8200 rubles.
- Presser 1 mini No. 2 – machine for 1 block, equipped with a 170 W vibrator with a pressure frame. Costing from 6340.75 rub.
Mobile semi-automatic machines are distinguished by the presence of a matrix of several blocks and more powerful vibrators. When purchasing these units, it is necessary to take into account the availability of a flat area for the production of blocks. The cost of such equipment will be slightly higher:
- The SSh-1 V, SSh-2, SSh-3 units have a similar operating principle, are equipped with a 2-block matrix, with motors with a power of 300 W or more. They have a productivity of 40-90 pieces/hour, and may also have an additional vibrator included. The cost of such units starts from 13,600 rubles.
- Cinder block machines of the Comanche series allow the production of 2-4 modules per cycle. Depending on the model, they have a productivity of 60-120 pieces/hour and a power of 0.25-0.48 kW. The price varies from 25,000 rubles. up to 49,000 rub.
There are also such models as: Mars, Tornado, Layer, Dragon, etc. They have the same operating principle and differ in the number of blocks produced per cycle, power and type of void formers in hollow cinder blocks.
Stationary equipment is much more expensive and more labor-intensive to maintain. One of the disadvantages is the need to remove finished products, several pieces on a pallet at once. Such units can be either mechanically controlled - brick making presses, or automated - cinder block mini-factories.
Equipment for cinder blocks
Vibropress machines for the production of cinder blocks and sand blocks with manual loading of concrete mixture. The blocks are formed onto technological replaceable wooden pallets. The power of such equipment is 8.5 kW, productivity is 20-30 cycles per hour, 4-5 blocks are produced per cycle. The cost of such a mechanism starts from 300,000 rubles.
The cinder block mini-plant DMYF-10A is equipped with hydraulic steering and automatic moving method. The power of this equipment is 16 kW, productivity is 1300-1400 pcs./hour. You can purchase such a plant for 750,000 rubles.
Construction company
For the constant production of small and medium-sized batches of cinder blocks, it is best to use mobile models. They must be designed for the simultaneous production of 2-4 products.
It is important to choose the right machine for the production of cinder blocks, designed for constant operation under construction conditions. Models of such mechanisms must have a high speed of production of products with a minimum number of servicing workers. Most often, 2 people are involved.
The main problem when using a machine on a construction site is the organization of storage space for finished products. As a rule, for these purposes, a temporary warehouse is erected, which will protect the workpieces from external influences of weather factors. If this is not done, then during the drying process the cinder block can absorb a large amount of moisture, which will lead to loss of integrity of the product.
Large production volume
A professional vibrating machine for the production of cinder blocks is necessary for the constant production of large batches of products. These are stationary models with full process automation. The feedstock is supplied to special bunkers along the carpet line. After its preparation, a matrix with forms is filled using a dosing system.
The technological scheme for such production is developed individually. All parameters are taken into account - the optimal volume of output, workshop area, composition of raw materials, etc. The result is a high-quality cinder block that can be used for multi-story construction.
How to choose the optimal equipment for cinder block production? It is necessary to focus on the volume and speed of production of products. In this way, continuous production of products can be organized.
