Aerated concrete production

Cellular concrete is actively replacing traditional wall stones. And this is due to their truly unique properties. “Aerated concrete blocks have almost perfect geometry,” says the honored builder Vasily Konev. "Plus, they stick together, thereby nullifying the cold bridges."

This means that the construction of buildings in terms of labor costs is sharply cheaper, which more than covers the higher costs of the glue used (cement mortar used in the laying of brick buildings is cheaper). In addition, a modern real estate buyer prefers aerated concrete because he is interested in purchasing more energy-efficient properties.

Unmissable perspectives

The fact that builders vote for aerated concrete is also evidenced by statistics. Every year there is a displacement of other positions by this wall building material, including brick and foam concrete. By the way, last year there was an increase in the consumption of aerated concrete by 4.7%, while per capita demand in Russia was only 25 m 3, while in the most advanced regions, for example, in Moscow and the Urals, this figure is 96 cubic meters ...

If we take, for example, the Krasnodar Territory, in which the consumption of this building material per inhabitant is only 49 m 3, then we can predict a doubling of demand over the next decade. The picture is the same in most other Russian regions. Let's try to figure out how difficult it is to occupy a niche in this market.

Easy to start

According to the majority of business angels, who, figuratively speaking, “ate the dog” at startups, a newly-minted entrepreneur, or even more so an experienced investor, should have clear and transparent conditions for starting. In this regard, the most interesting are ideas for business, the implementation of which will require a minimum of space and personnel.

“According to our data, people are more willing to go to businesses that require production facilities of up to 100 square meters. meters and a brigade of hired workers of up to five people, ideally two workers, - says small business expert Igor Malyugin. - With regard to the production of aerated concrete, we should talk about the complexes "Felix-10" with a capacity of up to 10 cubic meters per day and "Felix-20" - up to 20 m 3. These complexes just fit into these parameters "

• the required number of workers per shift - two;

• energy consumption per shift - 58 kWh;

• the cost of this equipment is only 225,000 rubles.

The same requirements are true for "Felix-20", with the difference that energy consumption per shift is 126 kW / h, and the price is 496,000 rubles.

This is enough to provide a small construction company specializing in the construction of cottages with wall stones of our own production.

Aerated concrete (not to be confused with foam concrete) is a fairly popular and popular building material in low-rise construction. At its affordable price, it has excellent performance characteristics that surpass concrete and wood in some parameters. The production technology of this material is very simple, so investments in the opening of the production of the demanded "gas stone" are not very large.

The aerated concrete business under certain conditions can really become a profitable starting point for entering the world of commerce. However, as with any commercial endeavor, there are pitfalls here. We will tell you about the nuances that you should pay attention to if you are fired up with the idea to organize your own production of aerated concrete.

Demand and Outlook

According to the Academy of Industrial Markets, the demand for aerated concrete in 2021 in Russia came close to 50 million cubic meters. Experts say that the sale of this material is one of the fastest growing markets with impressive dynamics: since 2021 it has grown almost 10 times from 5 million cubic meters.

At the same time, experts speak of serious prerequisites for growth. According to the Ministry of Construction, in 2021 the volume of housing construction amounted to about 54 million square meters, more than half of which (60%) is a "low-rise building". This is the main construction segment with a high consumption of aerated concrete. By 2021, the ratio of high-rise buildings / low-rise buildings may reach 20 and 80%.

And one more encouraging fact for potential producers of aerated concrete. According to the company "Metem" (one of the largest manufacturers of industrial equipment for the production of aerated concrete), since 2021, the supply of this building material significantly lags behind demand. This gap has already led to a 1.6-fold increase in the capacity of new enterprises.

Trends in the regions depend on the socio-economic situation, but they can also be estimated. For those who are seriously going to organize the production of aerated concrete, it would be quite reasonable to analyze the expected figures for the commissioning of new housing. First of all, you need to pay attention to the "low-rise building" - cottage and suburban settlements, sites intended for development under the Federal Programs "Affordable Housing" and "Low-rise housing construction". These figures can be easily found on the official websites of the administrations of republics, territories and regions. Trends in your area are immediately clear.

So, the trends in demand for aerated concrete are quite optimistic, the product will be in demand under certain conditions. What is needed to produce it?

Investments and Technology

Aerated concrete production technology has been known for over 60 years, but this material came to our country relatively recently. The properties of this cellular stone were immediately appreciated by professional builders. In terms of its strength, it approaches monolithic concrete, and in terms of thermal conductivity, it approaches wood. The large volume of gas in the material - up to 85% - makes its price very affordable. The lightness of aerated concrete allows you to save on foundations (the cost of traditional ones can reach up to 30% of the total construction budget), use piles and shallow foundations.

Aerated concrete production technology includes several stages:

• Preparation of aerated concrete mortar. Raw materials: cement, sand, water, reinforcing additives (polypropylene fiber) and foaming agent.
• Pouring aerated concrete array into molds.
• Cutting the array into blocks.
• Heat treatment.
• Dismantling the array into finished products.

As new technologies develop, the amount of initial capital that an entrepreneur must invest in promoting a business grows. Finding a profitable business that can be started from scratch is not easy today. One of the ways to get income in a short time is to organize a mini-plant for the production of aerated concrete blocks. It does not require huge capital investments and large production areas. It can be served from 2 to 8 people.

How to start a mini-plant for the production of aerated concrete blocks: a short instruction

Today, the construction of "heavy" houses from pure concrete and bricks is a thing of the past. Builders prefer to work with lighter, more convenient and cheaper materials. The demand for aerated concrete blocks is growing. Both utility rooms and residential buildings are built from it. If you are building your own cottage, an aerated concrete plant can be organized right on the construction site. But for large-scale production of blocks for sale, it is better to purchase a conveyor line. The specifics of installing such a plant on the official website of AltaiStroyMash are covered in sufficient detail. Also our consultants are always in touch!

To launch a mini-plant for the production of aerated concrete blocks, you must go through the following steps:

• find a room with a water and electricity supply;
• contact our company regarding the purchase of equipment of the required capacity and delivery to your region;
• buy consumables (sand, cement, additives and aluminum powder - a blowing agent);
• hire workers (if the plans do not include working at a gas block manufacturing plant yourself);
• find channels sales of products.

The equipment supplied by our company includes a mixer-activator, a cutting device, and molds for the production of aerated concrete products. You will receive everything you need to work, if you wish, you can launch a mini-plant in 24 hours!

How to get aerated concrete: the nuances of technology

The construction of a large format aerated concrete plant with the installation of a conveyor line will require the installation of a rail system and training of personnel for its maintenance. But a stationary mini-plant takes up a minimum of space, it is served by two pairs of working hands.

The production technology is the same for all manufacturers. The mixer mixes cement, sand, water and additives. Before pouring the mixture into the mold, add aluminum powder - a blowing agent that acts like yeast in the production of bread. The mixture rises and solidifies. After that, the massif is cut into separate blocks and, after the final curing, is removed from the molds and packaged.

The plant price for aerated concrete depends on its format and configuration. Stationary installations are inexpensive, but produce less. Large conveyor lines will cost more, but allow you to organize a large-scale business with a good income.

The modern pace of construction requires special materials. Recently, cellular concrete (aerated concrete) is gaining the greatest popularity. The production of aerated concrete is a profitable and demanded business. Moreover, this material stands out among others for its qualities. So, it is aerated concrete that has the best heat transfer in comparison with the rest. In addition, it is also energy efficient and lightweight. This makes it irreplaceable in construction and, therefore, in sales. The demand is unusually high. However, the competition for him is high. In almost every region there are several firms engaged in such production.

Business Investments

Of course, the production of aerated concrete cannot occur without investment. First of all, this is documentation. All permits and registration will take about 5-18 thousand. The exact cost depends on the region and the appetite of the registration officials.

Secondly - the premises. It should be spacious. In addition to the workshop where the building materials will be produced, a warehouse for finished products and premises for personnel are also needed.

Thirdly - our own fleet of special equipment. Of course, you can hire cars that will deliver your products to customers, but renting will eventually cost a little more. Perhaps, at first, you want to save money by not providing delivery services. This is not entirely correct, because then your customers can run away to those firms that provide delivery. It is better to think in advance about your own fleet of equipment, especially since you can also make money on it. Set a shipping rate, and then your fleet will pay off on its own.

Fourth, equipment for the production of aerated concrete. There are two options. If the start-up capital is not constrained, then you can buy a fully automatic line on which only a couple of people can work. Its cost starts at 3.5 million rubles. In total, such a line produces about 100 cubic meters of material per shift. If the starting capital is limited, then you can purchase a semi-automatic line. Its cost starts from 150 thousand rubles. True, the productivity is also lower - only 2-3 cubes per shift. What exactly to choose is up to you. If you are planning a large-scale production, then you cannot do without an automatic machine. If the plans include average sales and deliveries, a semiautomatic device will be enough.

In addition to all of the above, you need to hire staff. In addition to the workers following the lines, movers and drivers are needed. The number of employees is individual, depending on the scale of production.

And of course, it's a consumable. Your production is impossible without it. You can buy it both from domestic manufacturers and abroad. The first option is more budgetary, especially since it does not differ in quality from the foreign one.

Payback, revenues, profitability

Aerated concrete production pays off pretty quickly. If your production is medium-sized, with a semi-automatic line, then the payback will come in a year and a half. If the scale of performance is large, then it will pay off much faster. From 250 cubic meters of material per month of net profit, you can gain about 200 thousand rubles.

Aerated concrete is a building material. An artificial stone with spherical air pores. Starting entrepreneurs are thinking about creating a business, which includes the creation and implementation of a product. But first you need to draw up a business project for the production of aerated concrete.

Relevance of this business

Nowadays this project is in great demand. Novice entrepreneurs are interested in how to launch this project to create quality material. It is attractive because the payback period is short, because many people use this type of stone during construction. Aerated concrete parameters: 10 * 30 * 60 cm and 20 * 30 * 60 cm. It has a large number of positive qualities:

Therefore, consumers choose this product. The product includes the following components:

Stages of organization

Determine how large your enterprise will be, what type of product you will produce. There are two types of material fabrication:

In order to produce aerated concrete by 1 method, you need to temper it in an autoclave with steam. To make the material according to method 2, it is necessary to dry aerated concrete using heating.

From the data on how much production will be and what type of material is suitable, you can determine the area of ​​the premises, the number of equipment and the number of employees.

To produce 1 cubic meter of blocks you need:

With such data, it turns out that the cost price is equal to 1,500 thousand. It turns out that the minimum price for 1 cubic meter is 2,500 thousand.

Business plan for the production of aerated concrete blocks:

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