How to make foam block: production technology and specificity of equipment choice
Some manufacturers of foam concrete use special mixers in their work, others prefer mixers with ready-mixed foam from a special foam generator, and still others use dry foam mineralization.
If we consider the classical technology for the production of foam blocks, it is important to note that in accordance with it, the prepared foam must be mixed with the mortar mixture. And this principle is reflected in the work of all the types of equipment listed above.
The blowing agent concentrate and a certain part of the water are dosed according to the volume, and then they are mixed in a foaming agent. From there the mixture enters the foam generator, where it is brought to the required condition. Simultaneously, a mortar mixture is prepared, which includes sand, cement, fiber and calcium, and this product is combined with the foam in a special mixer. This is how the foam concrete is formed, and then it comes directly to the place of packing or in pre-prepared forms for the blocks.
Manufacturing technology for foam blocks: injection molding or cutting
After the construction mixture has been prepared, proceed directly to the production of foam concrete blocks. They can be manufactured by injection molding or by cutting technology. Moreover, according to experts, the foam block, whose manufacturing technology was cutting, has a more rough surface, which makes it easy to apply plaster or other finishing materials to it. But to produce such blocks is somewhat more complicated than cast ones, due to what they got a smaller distribution on the market.
Injection molding technology for foam blocks implies the use of special metal cassette molds with clearly defined cell size. In these forms fill in the finished foam concrete, after which it just has to freeze. Filling the mixture into molds is done without using vibration - the surface of the foam concrete is only leveled with a special metal ruler. A form-release after solidification of the mixture is carried out in stages:
- knock out locks of the mold;
- tilts the sides;
- removes dividing partitions, which form separate cells;
- extract ready blocks;
- lay out the finished blocks on a special wooden pallet.
Moreover, the foam blocks, whose manufacturing technology was injection molded, were extracted from the mold with the help of special mechanical tools and tools. And manual labor is of no small importance here.
It is important to note that foam blocks made by injection molding technology often differ in strength and density. In addition, their geometric dimensions can vary somewhat( as a rule, within the limits of 1-5 mm).Yes, and the manufacture of special metal forms can be associated with certain difficulties. Therefore, manufacturers in each case individually decide whether to give preference to the casting or cutting technology of making blocks, carefully weighing all the advantages and disadvantages of both methods.