Polystyrene concrete blocks: reviews of built houses

The use of various concrete blocks with a cellular structure is becoming increasingly popular, as this building material has low thermal conductivity and provides increased energy efficiency of the structure.

Plastering walls made of expanded clay concrete blocks, as well as gas silicate, foam concrete and other similar blocks has some differences, which we will discuss in this article.

Plastering on concrete blocks has its own characteristics.

Areas of application of expanded polystyrene concrete

Polystyrene concrete building blocks for rough masonry vary in size and purpose.
Composite material is used for the manufacture of such masonry and finishing materials;

• ordinary building blocks;
• masonry blocks with a molded (decorative) front side;
• reinforced (reinforced) building products;
• thermal insulation boards;
• finishing panels for facade cladding.

Polystyrene concrete building blocks for rough masonry vary in size and purpose. The building material for the construction of the main walls is made with a density of 500-600 kg/m3 and block sizes of 300x380x588 and 188x300x588. Products for laying internal partitions can have a lower density (from 400 kg/m3) with dimensions of 92x300x588.

Blocks for finishing masonry of an external wall with a textured (decorative) front surface have a density of at least 500 kg/m3 and standard dimensions. With the help of such masonry blocks, a finished facade surface is formed that does not require further finishing. The photo shows a sample of finished masonry made from this building material.

Blocks for finishing masonry of an external wall with a textured (decorative) front surface

Door and window beams, which are produced in lengths of 1.3-4.2 m, are reinforced with steel rods. They simultaneously perform the functions of structural reinforcement and thermal insulation.

Another type of products that are produced on the basis of composite material are panels for external wall cladding. Decorative slabs are available in two versions. Some of them are designed for sheathing walls (ventilated facade), others are designed for installation directly on the surface using mounting adhesive.

Reviews

Many experienced builders speak positively about this building material. Some of them say that this is one of the best solutions in terms of price-quality ratio. The material is highly durable and frost-resistant. At the same time, construction work with polystyrene concrete does not require much labor. It has thermal conductivity, which allows you to maintain the desired temperature in your home. Also, people who have used blocks from this material claim that it is truly durable.

Errors

The main mistake that many novice finishers encounter is the incorrectly selected composition for applying a layer of plaster. The wall has many nuances with such blocks, so it is worth taking these features into account when making calculations.

The selected mixtures must be mixed and mowed according to strictly specified proportions, otherwise there is a high probability that at the end of the season such plaster will begin to deteriorate and fall off. It is also not worth making the mixture yourself without knowledge and experience. This can only aggravate the situation and within a few years the plaster will lose its original appearance and completely collapse.

Subtleties of construction

You can build a residential building from expanded polystyrene concrete with your own hands quite quickly. If necessary, blocks of concrete and polystyrene can be made independently at home, following the manufacturing technology.

• Preparing the foundation. For buildings made of polystyrene concrete, a strip foundation is made, the bottom of which is covered with sand and gravel. For a structure of this type, the foundation height is chosen to be 70 cm.
• Construction of walls and roof. To strengthen the walls, a mesh of metal reinforcement is used. The blocks are installed with a seam size of no more than 0.8 cm. The blocks are fastened with an adhesive composition or masonry mortar. When the walls are ready, metal channel ceilings are installed and the roof frame is assembled. Waterproof plywood sheets are fixed to the frame and bitumen shingles are laid.
• Installation of insulation and finishing. After the walls are erected, they can be covered with insulation and the outside can be decorated with protective decorative finishing. Inside the building, the wall surfaces are finished with a thick layer of plaster. Outside, red hollow brick can be used as additional sound and heat insulation. For the ceiling during construction, ready-made large-sized blocks with thermal insulation characteristics are used.

You can build a house from polystyrene concrete in a few months, and its performance properties will be used for many decades.

Plaster of cellular blocks

Features and differences

Before plastering polystyrene concrete blocks, they should be prepared.

Finishing walls made of cellular concrete blocks often causes difficulties, since during drying or after some time the layer of plaster becomes covered with numerous cobweb-like cracks, and sometimes even begins to fall off. In addition, significant shrinkage of the layer may occur, and as a result, the finished surface begins to follow the relief of the masonry instead of hiding irregularities .

Improper preparation and selection of materials lead to cracking.

This is caused by the characteristics of the surface and structure of the blocks themselves:

• The material consists of concrete insulation foamed with gas or diluted with granules of concrete insulation; as a result, the structure of the material is heterogeneous and has many pores through which it actively absorbs moisture. As a result, the normal maturation regime of the plaster mortar is disrupted, it dries out and cracks;
• Pores that are not properly filled draw moisture into the solution material, resulting in severe shrinkage of the layer. Due to this shrinkage, the geometry of the surface is disrupted, and the wall becomes uneven, or masonry seams and block contours appear on it;
• A large number of pores and inclusions of foreign materials weakens the adhesion of the finishing layer to the surface. If measures are not taken to enhance adhesion, the finish can quickly crumble and fall off;
• The material of the blocks has high vapor permeability. As you know, when finishing walls, vapor permeability should increase from the inside out, so it is necessary to correctly determine what is best for plastering walls made of expanded clay concrete blocks;
• Cellular concrete strongly absorbs moisture, so the exterior of the house must be moisture-resistant, durable, frost-resistant and elastic. Modern polymer-cement mixtures meet these requirements.

The photo clearly shows the porous structure of the material.

There are also differences between blocks of different composition:

• Gas silicate, aerated concrete and foam concrete blocks have the most porous structure and require special surface preparation for plastering. As a rule, such materials are primed with cement laitance and deep penetration polymer compounds, and also reinforced with plaster mesh;
• Polystyrene concrete blocks contain polymer granules, so their surface properties are heterogeneous, because concrete and polystyrene have very different adhesion and moisture permeability. The finishing of such walls is carried out only using plaster reinforcing mesh, and it should be noted that the solution shrinks less;
• Cinder blocks and expanded clay concrete are plastered in the same way as ordinary monolithic or brick walls, since these materials do not have significant differences. In this case, it is also advisable to thoroughly prime and reinforce the surface, and use a plasticized solution with polymer additives.

Polystyrene concrete has many polymer granules in its composition.

Important! The technology for applying plaster over blocks does not differ from the classical one; the main differences relate to the preparation of the base, reinforcement, priming and selection of materials.

Materials

A ready-made specialized mixture is what is best for plastering cinder block walls.

The correct selection of materials is of great importance when finishing cellular concrete.

The solution must meet a number of requirements:

1. High strength. Cellular materials, as a rule, are not durable, so they need protection from wear, abrasion, shock, scratches and other mechanical damage;
2. Moisture resistance. The porous surface actively absorbs moisture and gets wet, so the outer walls must be finished with a waterproof layer;
3. Good adhesion. The surface and structure features of cellular concrete require increased adhesion to the cladding layer, otherwise it will simply fall off. It is advisable to use mixtures based on cement binder and various additives that increase adhesion;
4. Plastic. The layer must withstand minor changes in surface geometry as a result of temperature changes and shrinkage processes. To do this, it must contain polymer plasticizers and other substances that will make the dried layer flexible;
5. Frost resistance. For outdoor work in the Russian climate, only frost-resistant materials should be used.

Such a composition can be prepared independently on the basis of a cement-sand mixture with the addition of PVA glue and reinforcing fibers, however, preparing it yourself leaves some risk, since it is impossible to maintain the exact recipe under such conditions. Therefore, we will not focus on this topic, but will immediately move on to a more suitable option.

You can strengthen the solution with fiberglass and PVA glue.

This option is to purchase a ready-made plaster mixture for cellular materials. You can find such material in any construction market; the packaging will indicate the purpose: “for aerated concrete blocks”, “for cellular concrete”, “for porous surfaces”, etc.

The price of such a mixture will be higher, but attempts to save money can lead to the loss of much more money as a result of the rapid destruction of the finish.

Use special mixtures from trusted manufacturers.

In addition to the solution, you will need a primer composition and a reinforcing mesh. For priming, compositions based on polymer dispersions, quartz soils or concrete-contact mixtures should be used.

The material must be marked that it is intended for processing absorbent, cellular and porous materials; a composition for leveling absorbent abilities is also suitable.

It is important to choose the right primer.

Reinforcement can be done using galvanized steel mesh or fiberglass mesh for plaster. For a large layer of material, it is better to use metal reinforcement, and for a thin layer, glass reinforcement. When purchasing fiberglass mesh, choose a material with a density of 200 g/sq.m. and a cell of 5x5 or 10x10 mm.

Important! The correct choice of materials significantly increases the likelihood of successful completion of the work, and also has a positive effect on the further operation of the finish.

Pros and cons of polystyrene concrete blocks

Despite the fact that polystyrene concrete blocks began to be used in construction relatively recently, the main advantages and disadvantages of this material can already be identified. The undeniable advantages include:

Important! Minimum thermal conductivity is characteristic of a polystyrene concrete block with a minimum specific gravity. As the density of the material increases, thermal conductivity increases

• High sound insulation properties
  . In this indicator, polystyrene concrete blocks are also superior to brick, wood and other lightweight concrete. Sound insulation capacity is about 70 dB.
• Economical
  . The economic effect of blocks consists of several components. First of all, this is the affordable price of the material. In addition, low thermal conductivity allows you to save money on additional thermal insulation and reduce the thickness of the walls.
• Ease.
  The low weight of polystyrene concrete blocks significantly speeds up construction work and simplifies transportation. In addition, such buildings do not require a massive, expensive foundation.
• Environmental safety
  . The blocks contain predominantly natural ingredients that do not pose a danger to humans and the environment. As for polystyrene granules, oxidation of the polymer is possible at a temperature of at least +110C. This temperature can only occur in the event of a fire.
• Minor shrinkage
  . For dense brands of polystyrene concrete, this figure is 0.7 mm per 1 m. This is more than for natural stone and heavy concrete, but less than for wood and cellular types of concrete.
• Biological resistance
  . The material is immune to biological influences. Moss does not grow on the surface, mold and other fungal colonies do not form. Polystyrene concrete blocks do not attract insects and rodents.
• Hygroscopicity
  . Water absorption by weight is no more than 8%, while for brick this figure ranges from 12 to 15%, and for gas and foam concrete more than 14%.
• Frost resistance
  . In accordance with GOST requirements, various grades of polystyrene concrete can withstand from 35 to 300 freeze-thaw cycles.
• Ease of machining
  . No special tools are required to process the material. Polystyrene concrete is easy to cut and drill. If necessary, the blocks can be given any configuration.

The disadvantages of polystyrene concrete blocks include the following:

• Due to the loose structure of the material, installing dowels and anchors causes serious problems. It is recommended to install fasteners in cavities filled with M150 concrete, choosing the maximum length of hardware;
• When installing windows and doors, it is necessary to strengthen the door and window openings. The loose structure of the building material does not allow window frames and door frames to be attached directly to polystyrene concrete. The situation is further complicated by the fact that currently no unified reinforcement technology has been developed;
• insufficient vapor permeability. Polystyrene concrete requires effective exhaust ventilation. Otherwise, there is increased humidity in the room, the risk of mold, fungi and a general deterioration of the microclimate increases;
• the ability to intensively absorb water vapor negatively affects the frost resistance of the material. In addition, excessive moisture saturation can lead to deformation of the blocks. This may result in cracks, peeling of the plaster, etc.

It should also be noted that most of the disadvantages of polystyrene concrete are aggravated if:

• manufacturing technology is not followed or masonry work is performed incorrectly;
• the material is not used for its intended purpose. For example, instead of structural-thermal-insulating blocks, thermal-insulating-structural or thermal-insulating blocks are used;
• Specific climatic or soil characteristics are not taken into account.

Polystyrene concrete plaster

A house made of this building material requires additional processing. There are two ways to plaster such surfaces. The first method will not require significant financial costs, the second will cost more.

1. Dilute thin cement milk and spray it all over the wall. Dried polystyrene concrete walls will be easier to plaster with mortar. After treatment it will hold tighter. The method has a drawback: shrinkage of the building will lead to cracks appearing on the plastered walls.
2. Despite the high cost of funds, this method will give a more tangible result. You need to fill the surface of the wall with a plaster mesh (twenty by twenty millimeters cells) and secure it with wire staples. You can make them yourself, this will help save money. The staples are hammered in with indentations of up to thirty centimeters. Then the plaster should be applied. Reinforcing the mortar layer helps prevent the appearance of numerous cracks. After this, the house may become covered with microcracks (which is quite normal), but there will be much fewer of them.

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Construction Materials

To build a Swedish stove with your own hands, not counting the construction of the pipe, you will need materials and stove fittings in the following quantities:

Types of plastic blocks

Polystyrene concrete products are divided into the following types:

• thermal insulation. They are characterized by reduced specific gravity and reduced thermal conductivity. Unable to bear significant loads;
• structural. A distinctive feature of structural blocks is increased density and increased thermal conductivity. In demand for the construction of capital walls;
• structural and thermal insulation. They are used in the field of low-rise construction. They combine the properties of thermal insulation and structural products.

Products differ in design features depending on the specific application:

• partition elements are used to divide the room into functional zones;
• ventilation products have spilled cavities used for laying utility networks and ventilation ducts;
• facing products are a sandwich made of polystyrene concrete block and decorative finishing;
• lintels reinforced with reinforcement are indispensable when arranging openings for various purposes.

Plastic blocks also differ in overall dimensions.

Various types of products allow them to be used for finishing and other types of work

Masonry

An integral part of the masonry is reinforcement.
The masonry process involves pouring polystyrene concrete into a special wooden formwork. It needs to be done in advance. At the same time, the inside of the formwork is lubricated with motor oil.

To strengthen the walls, it is necessary to fix a mesh of reinforcement in the mixture. Almost anyone can do this kind of work.

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Plastering polystyrene concrete blocks

When finishing polystyrene concrete blocks, there are often no nuances or difficulties, but you need to know a few basic rules that should be followed when plastering walls:

• Polystyrene concrete has good adhesive properties, so the surface of the blocks will practically not absorb moisture from the plaster. The drying speed will be slightly higher than in the case of brick and aerated concrete.
• In order to plaster polystyrene concrete blocks with high quality, you need to use mixtures of a special elastic composition that could adapt to temperature fluctuations. This is due to the fact that polystyrene concrete is subject to linear expansion.
• In order for the mixture to spread as evenly as possible, it is applied to a previously wetted surface. This is the only way the plaster will not slide off the walls.
• For more effective attachment, plaster, both external and internal, must be reinforced. What are metal and nylon meshes used for?

Characteristics

Polystyrene concrete is a relatively new building material (it appeared on the construction market about ten years ago). New technologies make it possible to improve products made from this material, which expands the scope of application of polystyrene concrete mixtures. It is used to make blocks, slabs, etc. Polystyrene concrete blocks are rectangular in shape and impressive in size. These features simplify construction work. Plastic blocks have other characteristics, including:

• frost resistance;
• low degree of thermal conductivity;
• reliability;
• environmental safety;
• soundproofing.

Negative and positive aspects of using materials

Polystyrene concrete blocks have their pros and cons. Let's list the main advantages: reduction in material costs that would be required for additional insulation and heating of premises, variety of construction work (blocks can be given different shapes), fire and frost resistance, durability, sound insulation. To build a house, you do not need to use special equipment: the weight and size of the blocks allow you to do without it. In addition, polystyrene concrete is environmentally safe. The material does not rot because microorganisms do not grow in it.

However, the building material has its disadvantages, despite its advantages. Experienced builders note disadvantages that often appear due to improper manufacturing of blocks. Although polystyrene concrete structures are difficult to burn, fire can affect their strength. A house made of blocks is prone to microcracks and shrinkage. To avoid this, special fibers are added to the solution. This must be taken into account when making materials with your own hands. Experts also point out other disadvantages, in particular, low-quality filler or its lack leads to a decrease in the properties of plastic blocks. Therefore, the manufacture of products requires strict adherence to the rules and proportions for mixing the solution. There are also less significant disadvantages of building materials: a house made of polystyrene concrete requires plaster, which increases the cost of finishing the building. Additional disadvantages are also known: the products have poor adhesion to the plaster solution. It is necessary to prepare polystyrene concrete blocks before covering the surface.

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Application of polystyrene concrete

GOST 22929-2016 regulates the production of polystyrene concrete grades D150-D600. A three-digit number is the average density in kg/m3.

On sale you can find brands D800–D1200. Based on the experience of neighboring countries, many practicing builders consider lightweight PSB to be a promising analogue to expanded clay concrete. Density up to 1400 kg/m3 does not contradict GOST 27005 - 2014, but the properties of such PSB are largely up to the manufacturer.

The correspondence of brand, strength and scope of application is presented in the table:

The range of finished products made of polystyrene concrete includes:

Masonry (wall) blocks of different brands. The size range is wide - you can choose convenient dimensions for any project.

Partition structural and thermal insulation blocks are distinguished from masonry blocks only by their shape: running dimensions 92*300*588 and 135*300*588.

Reinforced floor slabs 30 cm thick, 110–150 cm wide, 3 to 6 m long. The slabs are installed as interfloor, attic, end floors, external and end load-bearing walls.

Reinforced concrete lintels for window and door openings are of different heights and lengths, the dimensions are chosen taking into account the size of the masonry blocks.

Thermal insulation boards for facades, floors, warm suspended ceilings, cladding of concrete columns. It is enough to plaster or prime the slab and protect it with paint.

Tongue and tongue blocks. The exact dimensions and shape allow the construction of external walls without additional insulation from the outside - the house turns out to be large-panel, but without “cracks”.

Other characteristics of polystyrene concrete depend on the brand in terms of density; below is a table of properties based on GOST-33929–16 “Polystyrene concrete. Technical conditions".

Briefly about polystyrene concrete: composition and properties of the material

To successfully start production, in addition to organizational issues, you must first become familiar with the characteristics of the material and the composition of the raw materials. Agree, it would be stupid to release something you know nothing about.

Structure of polystyrene concrete

So, polystyrene concrete is a representative of lightweight concrete. It is distinguished by the presence of polystyrene and concrete crumbs in its composition, as well as specialized additives that increase the characteristics of the mixture and products made from it.

Polystyrene concrete blocks: composition

The polystyrene fraction can be different; it varies mainly depending on the desired density. The dependence is simple: the more polystyrene, the lighter the block, and its heat-saving ability is higher.

Polystyrene concrete crumbs

Let's move on to the main features:

• Like other types of lightweight concrete, depending on the average density, polystyrene products can be used as a thermal insulation or structural material. This figure can vary from 150 to 600 kg/m3.
• The thermal conductivity of the dry material begins to count from a numerical value of 0.05. In this regard, polystyrene concrete can be said to be a leader. The maximum value does not exceed 0.145.

Thermal conductivity and vapor permeability of polystyrene concrete

The finished structure, built using polystyrene concrete, will, of course, have a high coefficient - due to being in a state of operational humidity. However, there will be no significant changes.

Comparison of the heat-saving characteristics of polystyrene concrete with other materials

• Polystyrene concrete is characterized by a high frost resistance grade - it can reach 200. This means that the products can withstand up to 200 cycles of temporary freezing and thawing.
• It is also worth noting that polystyrene concrete is an environmentally friendly material; it does not burn. However, it is not able to withstand high temperatures for a long time.
• The durability of the products leaves no doubt. Much depends on the manufacturer, operating conditions, composition of raw materials and technically correct finishing. However, if all standards are met, polystyrene concrete will last an extremely long time.

Polystyrene concrete takes a leading position in durability

The strength grade is directly dependent on the density. The minimum value established by GOST is B 0.35.

Technical properties of polystyrene concrete:

Methods for combining concrete and foam plastic

Three main methods can be distinguished:

Insulation with pages

This option involves the creation of an insulating layer, in other words, the mentioned material is used with your own hands, like every insulation:

Placed under the screed before pouring.

Is it possible to insulate aerated concrete with polystyrene foam? In this case, yes. This is by and large a universal method that can be combined with any other building materials.

Expanded polystyrene has its own classification, which is detailed in the following table and will help you make the right choice:

Mixing

The instructions for mixing the combined solution look like this:

1. We load cement and sand into a concrete mixer in a ratio of one to two.
2. Then we fill in the same amount of foam chips. If there are no ready-made balls, then it is possible to pass entire pages of foam plastic or their remains through a special crusher.

1. After some mixing is completed, add water, the volume of which should be approximately half the volume of the loaded mixture.
2. Stir until the solution reaches a homogeneous state, reminiscent of buckwheat porridge.

As a result, it turns out that the non-specialized proportions of all components look like this:

The finished product will have the following advantages compared to pure concrete:

Reduced thermal conductivity. Significantly higher thermal insulation qualities due to the presence of foam particles.

• Light weight. Which indicates less load on the foundation. Moreover, it is much easier to work with such a solution.
• Increased sound insulation. Noise that may travel through the cement stone will be absorbed by the polystyrene balls.
• Lower price. Polystyrene foam is much cheaper than other concrete ingredients, especially taking into account the proportions used, which accordingly significantly affects the final price of the screed.

But one feature is still getting worse. This is strength. And in order for this parameter to remain within normal limits, you need to carefully monitor the ratio of the insulating additive in relation to other components.

Permanent formwork

The use of a permanent frame made of foam plastic for pouring concrete is a fairly progressive and effective way of constructing and insulating buildings, which provides many advantages:

Variety of poured designs. Expanded polystyrene formwork can have any shape: arch, column, beam, corner, and so on. This significantly increases the number of design solutions.

• Ease of handling. You only need to install the desired structure, which already has reinforcing rods, and fill it with cement mortar. In addition, there is no need for preliminary installation of wooden formwork.
• Ease of processing. Blocks are cut using a sharp knife without any special equipment; the same method is used to create grooves for electrical wiring.

• Solidity of the finished structure. The absence of joining seams gives additional advantages to thermal insulation and strength.
• High speed of installation work. A simple box of a small private house is built in seven days.

The only point that can be considered a minus is the need for external finishing work. But, if you want to end up with a building with a beautiful facade, then additional finishing will be useful when using virtually any building material. In this case, simple plastering is suitable.

Stages of the production process

Since we have become familiar with the material, it’s time to move on to considering production technology. And we will start with a list of necessary raw materials and equipment.

Necessary equipment and raw materials

The production of polystyrene concrete blocks involves the purchase of one of several line options:

The conveyor type line is maximally automated. There is practically no need to involve labor. It is distinguished by high cost and maximum return. Production volumes are usually large.

Products produced on such equipment will have good geometry and high performance due to the precise dosing of components and strict adherence to technology.

Economy class conveyor line

A stationary line is a more budget option. However, the main disadvantages are the need to attract additional workers and the limited number of products produced, which cannot be as large as when using a conveyor.

Any complete set of such equipment can be selected. The result partly depends on the availability of cars - and this is worth taking into account.

Stationary line for the production of polystyrene concrete, photo

For the development of small businesses, or for making polystyrene concrete with your own hands, a mobile installation is perfect. Its price is low, and productivity can reach 30 m3 per day.

The disadvantages of using the installation are the following: a high probability of errors when weighing the proportions of raw materials, since you will have to do this yourself; possible overuse of components due to partly manual production and inexperience.

Mini installation for the production of polystyrene concrete

The simplest and most inexpensive set is a set of a concrete mixer, raw materials and molds for products. If you plan to produce products exceeding a volume of 25-30 m3 per day, you will need to purchase a foam generator that can ensure an uninterrupted supply of the mixture.

As for the composition, the main components are, as already mentioned: polystyrene chips, cement, water and sand. Tree resin is often used as an additive.

Approximate proportions for the production of polystyrene concrete mixture

There is no exact recipe, there are only recommendations. Therefore, the presence of an experienced technologist in the team when opening a business is only welcome.

This is one of the reasons why products from different manufacturers can differ significantly from each other.

Description of technology

The production of polystyrene concrete can be done in one of two main ways: injection molding or semi-dry pressing.

The technology for the production of polystyrene concrete blocks by casting involves the execution of certain stages.

The instructions look like this:

• First, the ingredients are fed into the mixer in the required proportions;
• Mixing occurs;
• The finished solution is poured into molds, which are first recommended to be lubricated with a special composition. Diluted machine oil is also suitable;
• After a few days, the products can be stripped. In winter you will have to wait a little longer;
• Brand strength is achieved only after 28 days; before this period it is not recommended to use blocks in construction.

As a result, the products are of low or medium density. The basic procedure for work in factory and home conditions differs little beyond the level of automation. The technology for manufacturing polystyrene concrete blocks is the same in both cases.

Polystyrene concrete blocks: production technology using the casting method, diagram

The difference will be in the finished products. A block made with your own hands will probably not be so ugly and even - most likely, its geometry will be broken. Producing a high-density block yourself is also difficult.

Since the products are not controlled by anyone or anything, it is not possible to accurately state their characteristics. The second method is more effective and modern - vibrocompression.

Its essence is as follows:

1. The cement content in the solution is, as a rule, increased, and the water content is decreased. The mixture turns out very thick.
2. Using a vibropress, the products are brought to a semi-dry state.
3. The next step is to process the blocks in a drying oven.

The video in this article: “Production of polystyrene concrete blocks: manufacturing technology” contains some information about the stages of the production process.

Manufacturing

It is necessary to add all components to the concrete mixer in the correct sequence. You can mix the solution by hand in a large container. Then the mixture should be thoroughly mixed until a homogeneous consistency is formed. To prepare the solution you will need:

• pour PG, add water, add additives, stir for two minutes;
• add cement, mix for about three minutes;
• add tar (used as a water-repellent ingredient), mix again;
• pour the mixture into molds and leave to harden for a day;
• remove the plastic block, place it on a uniform surface until dry;
• two to three weeks later, polystyrene concrete is ready for use.

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Beautiful interior design ideas

Even from a one-room apartment you can make a unique living room, in which there will be a double bed, and your guests will feel very comfortable.

Cover the area above the head of the bed with dark brown plain wallpaper, in the corner of which a sakura branch “blooms.” For furniture, install wardrobes to match the brown wallpaper. A snow-white carpeted floor will lead you from the bed to a white sofa with contrasting brown pillows, above which there is wallpaper (almost white). You can add a little cream color and install the same light coffee tables. Accessorize by adding mirrors above the sofa to make the room appear larger. Opposite the sofa is a dark brown stylish chest of drawers where you can place a TV.

Two zones, light cream and dark brown, will turn your sixteen meters into an elegant room in which you can sit with guests and relax on the bed after a busy day.

All your fantasies and creative impulses (as well as advice from designers) can give you a beautiful and cozy home, allow you to find your own style and be proud of the result.

Performance overview

The material parameters are regulated by GOST 51263-99, grades are classified according to strength, density and frost resistance. The main operating values ​​include:

• Thermal conductivity coefficient is in the range of 0.055-0.145 W/m·K.
• Density – 150-600 kg/m3.
• Compressive strength – up to 3.6 MPa.
• Frost resistance – from 35 to 300 cycles.
• Vapor permeability coefficient – ​​no more than 0.5 mg/m·h·Pa.

Compliance with fire safety standards deserves special mention. Polystyrene concrete has a flammability group of G1 and is classified as a low-flammable substance with low and moderate smoke-generating ability (B1 and D1, D2). But it cannot be classified as heat-resistant and cannot be used as a fire-retardant material. Reviews note that when there is direct or close proximity to an open fire or areas with high temperatures, the polystyrene foam filler begins to collapse, which negatively affects the insulating and strength properties of the block. But for private construction it is suitable and fully complies with both fire and sanitary safety standards.

Reviews about blocks and houses made of polystyrene concrete

“I built a summer kitchen from blocks with foam chips with a density of 400, and during the laying process I was completely satisfied with the material. Among the advantages, I can note quick installation, lightness, good heat retention even without connected heating. I finished construction in the fall, didn’t have time to do the finishing, and then discovered some disadvantages. The windward side became almost completely wet during the winter cycle with good rain. The finishing work took a lot of money due to the need for a thick layer of plaster and reinforcement on both sides.”

Ivan, Krasnodar.

“I am the owner of a one-story cottage made of polystyrene blocks with a density of 500, laid in two rows. In my opinion, they have only one minus - poor vapor permeability, while the finishing was going on, the feeling of a steam room was created inside the room, but after that it went away. There are more advantages: quick self-installation, ease of processing, the house keeps heat well and for a long time, four years after the completion of all repairs there are no complaints.”

Ilya, Moscow.

“From my own experience in building a one-story house, I advise you to buy blocks only from certified manufacturers, preferably with a long history; I personally have come across many fakes. Polystyrene concrete has operational disadvantages, but these can be eliminated with the help of modern finishing materials. The advantages include good insulation properties; when laying in two blocks, insulation is not needed.”

Dmitry, Irkutsk.

“I used D300 polystyrene concrete blocks as insulation for an old cinder block house. I am pleased with the result: it became much warmer inside, saving on heating was 35 percent. The outer walls, unlike foam plastic, do not break with any impact, birds and mice have not disturbed the appearance in 3 years. So I recommend it as insulation.”

Sergey, Moscow region.

“I bought polystyrene concrete blocks when building a country house. What I can say from my own observation: look for a certified product, after installation, let the house sit for at least a year, there is a lot of shrinkage, although there are no cracks in the walls, but the plaster is bursting. There is also the problem of fasteners; everything is held together only by cement mortar. But in the end, the dacha turned out to be quite warm; to maintain heat in winter, it is necessary to warm it up sometimes and it lasts for a week (we live in it on short visits). So I’m happy with the material.”

Roman, Moscow.

“The walls of the carpentry shop, 20 by 5 m, were erected from polystyrene blocks, the thickness was 300 mm, they were plastered on the outside, and left unfinished on the inside. As a result, the costs were small, the heat remains even in frosty conditions of -25° without intensive heating. The downside is that there is no point in hanging anything on the walls (shelves fall down), only shelving helps. Also, after 2 years, I reinstalled the entrance doors (the hinge was completely loose), and I had to cover everything with mortar at the fastening points.”

Andrey, Yekaterinburg.

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Installation

Plastering of expanded clay concrete blocks is done manually.

Let's move on to practice.

The following are step-by-step instructions for applying plaster to a wall made of cellular blocks:

1. We clean the wall surface from dust, dirt, grease and oil stains, old finishes, etc.;

Clean the surface.

1. We putty the seams and cracks so that they are flush with the general plane of the wall. We use a cement-sand mixture or a ready-made plaster solution, you can buy putty for the seams;

We process the seams.

1. After the joints have dried, carefully prime the wall. When the primer has dried, you can prepare a solution of cement and water (cement laitance) and apply it to the wall with a brush in horizontal strokes, this will increase the adhesion between the materials;

Apply primer.

1. We stuff reinforcement mesh onto the wall. You can use steel U-shaped brackets or anchors with wide washers made of thin metal;

We install the plaster mesh.

1. We set the beacons using plumb lines or a level. The pitch between profiles is 1.3 – 1.6 m (for the two-meter rule). We attach the lighthouses to cement mortar;

We display beacons.

1. Prepare the plaster solution in a wide tray, trough or bucket according to the manufacturer's instructions. Stir it with a mixer or shovel until the consistency of liquid mashed potatoes;

Prepare the solution.

1. We throw the mortar onto the wall using a ladle or trowel, smooth the layer with a plaster rule along the beacons from bottom to top, slightly moving the rule from side to side;

We throw the solution onto the wall and level it along the beacons.

1. We wait 6 - 7 hours for the first layer to set, then we remove the beacons and begin to apply the finishing layer using a grater or trowel, filling in all the unevenness;

Apply the finishing layer.

1. When the finish begins to set, rub it with a plaster float in a circular motion or in a staggered motion;

We rub the surface.

1. We wait for the plaster to dry completely, then we prime and paint it again. You can also finish it with decorative putty or other finishing material.

We do the final finishing.

Polystyrene concrete: technology, composition, formulation

Polystyrene concrete is a building material that contains granulated polystyrene (PVG - granular foamed polystyrene). Polystyrene itself is nothing more than polystyrene foam. Thanks to its presence, the product is lightweight and has good sound insulation properties. PSB is used for the following types of construction work:

• in monolithic construction;
• in classical house building;
• as insulation for walls, floors, roofs and other elements of the house;
• in non-standard situations.

Polystyrene concrete is poured into heat-insulating floors and light, non-loaded floors.

Industrially produced polystyrene concrete has the following technical characteristics:

• the material has a density of 150-600 kg per cubic meter (according to GOST R51253-99);
• PSB belongs to the G1 flammability group, therefore it is a low-flammable material;
• frost resistance starts from 25 cycles;

It should be noted that if PSB is produced by the artisanal method (independently at home), then the technical characteristics may vary, depending on the manufacturing technology and the proportions adhered to. It is impossible to determine the grade of PSB if the material was manufactured independently.

Polystyrene concrete comes in several grades, each of which has its own area of ​​application:

Polystyrene concrete as a material is produced in industrial production. In addition, polystyrene concrete blocks are manufactured specifically for the construction of walls. The blocks are large in size, so building walls is very quick. Polystyrene concrete has a simple manufacturing technology and formulation, so you can even produce it yourself at home. As well as polystyrene concrete blocks for building walls. This is another advantage of the material, because amateur builders can save a lot on the purchase of material. It is enough to buy polystyrene and cement itself, and you can get all the other components yourself.

In industrial production, the following components are used to produce polystyrene concrete:

• cement. Both Portland cement and Portland slag cement are used;
• granulated polystyrene. Polystyrene granules have different diameters;
• quartz sand;
• water;
• plasticizers, setting accelerators.

During factory production, proportions, temperature and time conditions are strictly maintained, which is why polystyrene concrete has guaranteed technical characteristics.

When producing polystyrene concrete in a factory, strict proportions are followed when mixing the component.

How to define quality?

In order to protect yourself from purchasing low-quality polystyrene foam concrete, it is important to know how to distinguish products made in accordance with GOST from counterfeits:

• delamination of the concrete mass with polystyrene granules is unacceptable, the structure of the material must be homogeneous;
• if crushed foam was used in the material, the quality of strength and thermal insulation ability of the blocks will be reduced;
• counterfeit polystyrene has large granules of 6-12 mm, the cellular structure of the material is disrupted and strength decreases;
• Defective products are considered to be deviations of blocks from standard dimensions by more than 3 mm;
• finished blocks should not contain waste polystyrene concrete in their structure, as this reduces the strength of the material.

Choice

When purchasing materials, you need to consider the following features:

• high-quality polystyrene concrete contains a lot of polystyrene granules (they are noticeable in sections);
• the sizes of the granules must be the same;
• voids are visible in low-quality concrete;
• it is necessary that the weight of the building material corresponds to the density;
• high-quality products have the appropriate certificates and documents from regulatory government agencies on all components of the material.

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