Foam blocks and gas blocks are popular building materials used for the construction of walls, partitions and other structures. They are distinguished by their lightness, thermal insulation properties and ease of processing. Special technological lines are used for their production, ensuring a high-quality final product.

Differences between foam blocks and gas blocks

Before considering the production process, it is worth understanding the difference between foam blocks and gas blocks:
• Foam blocks are made from cement mortar with the addition of a foaming agent, which creates a fine-pored structure of the material. This provides low thermal conductivity and lightness.
• Gas blocks are created due to a chemical reaction between cement mortar and aluminum powder. As a result of the reaction, hydrogen is released, which creates a cellular structure of the material.
Both materials have similar properties, but different approaches to production affect their characteristics and scope.

Main stages of foam block production

The production of foam blocks is characterized by simplicity and lower equipment costs. The process consists of the following main stages:
1. Preparation of the solution. Cement, sand, water and a foaming agent are fed into the mixer. The foaming agent is added last, as it ensures the formation of air bubbles in the solution.
2. Mixing. The resulting mixture is thoroughly mixed until a homogeneous mass is formed. At this stage, it is important to achieve foam stability so that the bubbles do not collapse during hardening.
3. Block formation. The mixture is poured into molds of the desired size. Molding can take place in both stationary and removable molds, which allows the production of blocks of various configurations.
4. Curing and drying. The blocks are left for initial hardening, and then they are moved to special drying chambers. This process takes from 24 to 48 hours, depending on temperature and humidity.
5. Demoulding and packaging. The finished blocks are removed from the molds, checked for quality and packaged for further transportation.

Main stages of gas block production

The gas block production process is more complex and requires special equipment:
1. Preparation of raw materials. The main components are cement, sand, lime, water and aluminum powder, which acts as a gas generator.
2. Mixing of components. The raw materials are mixed in special mixers until a homogeneous mass is obtained. At this stage, aluminum powder is added, which reacts with lime and releases hydrogen.
3. Forming and raising the mass. The resulting mixture is poured into large molds, where it rises, forming a cellular structure. This process is called swelling and lasts about 1-2 hours.
4. Cutting the blocks. After initial hardening, the mass is cut into blocks of the desired size using special cutting devices.
5. Autoclave treatment. For final hardening, the gas blocks are subjected to autoclave treatment under high pressure and temperature (180-200 °C). This ensures high strength and durability of the material.
6. Packaging and storage. After cooling, the blocks are packaged and prepared for shipment to customers.

Production equipment

For the production of foam blocks and gas blocks, various equipment is used, which can be divided into several main categories:
• Mixers for preparing cement mortar.
• Foaming agents for foam blocks, which add stable foam to the mortar.
• Molds for pouring and forming blocks of various sizes.
• Cutting devices for gas blocks, which ensure accurate product dimensions.
• Autoclaves - special chambers for autoclaving gas blocks.
• Conveyors and conveyors for moving raw materials and finished blocks along the line.

Advantages and disadvantages of production

Advantages of foam block production:
• Simplicity of technology. Does not require complex equipment, reduced production costs.
• Flexibility of production. Possibility of manufacturing blocks of various sizes and shapes.
• Low cost of raw materials.
Disadvantages:
• Lower strength. Foam blocks are less strong than gas blocks.
• Longer drying process.
Advantages of gas block production:
• High strength and uniformity of structure.
• Process automation. Possibility of implementing fully automated production lines.
• Dimensional accuracy. Minimal errors in block dimensions thanks to cutting devices.
Disadvantages:
• Higher cost of equipment. Autoclaves and special cutting devices require significant investments.
• Complexity of the production process. Requires control of many parameters (pressure, temperature, etc.).

Foam block and gas block production lines have their own characteristics and advantages. The choice between these materials depends on the specific construction conditions, thermal insulation requirements, strength and project budget. Investing in modern equipment and production technologies allows you to obtain high-quality blocks that meet the needs of modern construction and ensure the durability and comfort of buildings.
Enterprises engaged in the production of foam blocks and gas blocks can ensure stable demand for their products due to the growth of the construction market and increasing demand for energy-efficient materials.