ALTA-BLOCK
The fairly young Russian company ALTA-BLOK has been on the foam block market for only 5 years, but during its short existence it has significantly expanded its activities and occupies a prominent place among other construction manufacturers . Affordable prices for construction products allow us to work flexibly with our clients, who appreciate the professionalism and fast work. The range of different blocks for construction work includes products of various configurations. These are foam blocks with dimensions of 600 x 300 x 200 mm, 588 x 288 x 200 mm, 588 x 288 x 100 mm and other types.
The manufacturer also offers different densities of products, which can be used as load-bearing structures when constructing walls, or simply as partitions. Delivery is carried out by vehicles of different carrying capacity with a maximum tonnage of 20 tons. The company also offers expanded clay blocks for partitions, curb stones and mounting mixtures . At the same time, the company’s specialists can develop a house project, which can be over 300 square meters in area. meters and carry out its construction.
- Country of origin – Russia
- Company address: Moscow, st. Feodosiyskaya 1
- Manufacturer's website - https://www.altablock.ru
YugraBlok
The next manufacturer is a young and rapidly growing company that confidently holds a high position in the Russian foam block market. During its short existence since 2013, the company has managed to significantly expand its production capacity and achieve great results. For large developers, the company provides huge discounts while producing very high-quality products that meet all Russian standards and is ready to compete with the best foreign manufacturers.
The company can fulfill any wishes of customers regarding the size and density of foam blocks to meet all the client’s needs, including the construction of a house from blocks https://stroiproekt77.ru/dom-iz-blokov-moscow. The quality of the components from which the products are made is carefully checked by experts in order to avoid the consequences associated with the use of low-quality building materials in construction. All raw materials are environmentally friendly and have passed all state standards, including GOST 21520-89, while having precise geometric shapes and meeting all the parameters stated in the documentation. Moreover, all products are resistant to frost and have low thermal conductivity.
- Country of origin – Russia
- Company address: Surgut, st. Them. Glukhova 12
- Manufacturer's website - https://www.ugrablok.ru
The operating principle of a mini-plant for the production of foam concrete
The mini-plant is installed on support legs tilted to the side for convenient unloading of foam concrete from the mixer. A control panel is displayed on the panel of the mini-factory, which allows you to control the equipment from one place. Raw materials are loaded into a concrete mixer strictly according to technology, in certain proportions and in a clear sequence. Water is poured in, reinforcing fiber, cement, sand are loaded; then the components are mixed until smooth. The raw materials are loaded into the concrete mixer by 60%, and the rest is filled with foam. In the process of mixing the components, a foaming agent solution is prepared (for further supply to the foam generator with subsequent unloading of the whipped foam into the concrete mixer). In a concrete mixer, the formed foam is mixed with the solution for 7 minutes. The prepared solution is unloaded by peristaltic pumps into metal forms (or formwork, if the work is carried out on a construction site). The advantage of a peristaltic pump is that the high pressure of supplying the solution vertically makes it possible to use the pump as a device for washing equipment after a work shift.
Omsk Foam Concrete Plant LLC
A fairly well-known factory for the production of foam blocks from Omsk has high quality products that even sometimes scammers falsify low-quality blocks made in an artisanal way as products of Omsk Foam Concrete Plant LLC. In order to avoid such counterfeits, customers should contact the company’s managers directly on the manufacturer’s official website using the specified contacts. Having been on the market for a long time among the best manufacturers of foam blocks in Russia, the company knows exactly what the client needs.
In its work, the company adheres to several principles that help it develop successfully, creating a good reputation as a reliable and conscientious partner. This is a constant search for innovations and approaches to move forward , an individual approach to each customer, be it the smallest consumer, qualified specialists who carry out the entire production process and are involved in logistics and searching for customers. These three basic rules made it possible to create a truly successful and rapidly growing company.
- Country of origin – Russia
- Company address: Omsk, Mira Ave. 177
- Manufacturer's website - https://www.penoblokomsk.ru/
Business plan
Business plan for the production of foam blocks:
The financial side of the planned project is of great importance. The following components stand out in particular:
- Initial investment. At this stage, the necessary equipment for foam blocks is purchased. It is delivered to the production area. Approximate costs here lie in the range of 350,000 – 400,000 rubles. This is the price of equipment for producing foam blocks at home.
- An area is being prepared for the production of the intended material. Expenses: about 60,000 – 70,000 rubles.
- Materials and raw materials are purchased. The costs are the same as in paragraph 2.
- Special clothing and work equipment are purchased. Expense range: 110,000 – 120,000 rub.
In total, expenses can reach 600,000 rubles. Pays for itself in a reasonable amount of time, production of foam blocks, equipment, price for all consumables - all this can be solved even for a beginning individual entrepreneur.
Calculation of the cost of creating 1 cubic meter, production of foam blocks, equipment and more:
- Elements for creating a composition – 1450 rubles.
- Processing of a working form – 10 rubles.
- Depreciation of the equipment involved – 350 rubles.
- Electricity costs – 150 rubles.
- Payments to employees - 500 rubles.
In general, it turns out to be 2460 rubles, having equipment for foam concrete in your property.
Selling this volume costs 3,500 rubles. Income before taxes – 1040 rubles. When creating 100 cubic meters. per month profit reaches 104,000 rubles. Taking into account income tax (15%) per month it turns out to be 88,400 rubles. With this, the approximate business plan for the production of foam blocks can be completed.
But, if the created products are sold 100%, you can quickly recoup all investments. And then net profit will follow. In this case, it is very important to follow the fact of seasonality and take into account possible difficulties with the sale of your products. It’s not difficult to guess that buying equipment for the production of foam concrete is not everything.
URAL HOLDING
One of the most reliable and time-tested suppliers of building materials, including foam blocks of the highest quality . Working with the company, the customer receives full support, from production to final delivery to the construction site specified by the customer. The production volume of aerated concrete blocks is 1200 cubic meters. meters per month, which is quite an impressive size that can satisfy almost any construction project. The plant's products are used for the construction of cottages, civil, administrative and industrial buildings.
The product range includes a fairly impressive number of products of 5,000 thousand items. These are products made from reinforced concrete products, foam blocks, twin blocks, bricks, roofing materials, crushed stone, insulation and much more. The company's goals are quite simple - a warm home for every family, high rates of construction for the city, and high rates of development and use of innovation for other industries. products are delivered to any corner of vast Russia , and the customer's needs are addressed in full, be it a simple client represented by one person or an entire corporation.
- Country of origin – Russia
- Company address: Ekaterinburg, st. Radishcheva 6 A, office 206
- Manufacturer's website - https://www.ural-holding.com
Equipment issue
On the equipment market today you can find a sufficient number of necessary units for production. There are ready-made kits that do not even need to be assembled from components, but simply installed (which the supplier himself will do) and operate. The cost of the kit varies on the market from 300 thousand to 1.7 million rubles, and largely depends on the power of the equipment and the volume of production per unit of time. For a mini plant, very high power is not needed, therefore, when choosing a kit, you can focus on equipment in the minimum price category.
The set of equipment for the production of foam blocks includes:
- pressure unit;
- foam generator;
- compressor;
- forming trays (about 30 pcs.).
Thanks to the presence of such a set of equipment, it will be possible to organize the production of building materials in one shift (8 hours) involving the labor of 2-3 workers and at the same time produce up to 5 cubic meters. finished products. In monetary terms, this will be 10 thousand rubles per working day. In 20 days, it will be possible to produce 100 cubic meters. blocks with a revenue amount of 300 thousand rubles.
MARM
The MARM plant produces non-autoclaved aerated concrete or foam block, which has high quality and strength, which are ensured by the use of high-quality materials. This is the best cement, quartz sand, special gas generators , as well as gypsum and lime. All components undergo strict quality assessment and only after that are allowed for production of products. For better strength, the plant uses special technologies that make it possible to create high durability.
This is a fiber reinforcement technology , which consists of adding basalt fiber to the mixture, which significantly strengthens the structure of the hardened foam block. Impact resistance, abrasion resistance, corrosion resistance, frost resistance, water resistance are increased and cracking is significantly reduced. The monthly capacity of the plant is 3000 cubic meters. meters of raw materials, which is a very good indicator even for large construction projects. The company's clients have repeatedly been convinced of the reliability of the enterprise and the honest fulfillment of all its obligations.
- Country of origin – Russia
- Company address: Leningrad region, Vsevolozhsky district, village. Lepsari
- Manufacturer's website - https://www.marm-spb.ru
Production technology
Non-autoclave technology for the production of foam blocks includes the following steps:
- making a mixture of cement of a certain brand (the brand affects the strength characteristics of the product), sand and water;
- adding ready-made foam or foaming agent to the mixture (the hardening process can be accelerated by adding a hardener, for example, calcium chloride in an amount of 1% of the total volume of the mixture);
- distribution of the solution into molds coated with a special lubricant;
- drying during the day;
- removing the finished blocks from the molds, placing them on special pallets and further drying for two days.
Autoclave production reduces cement consumption by 1.5-2 times, reduces drying time, increases the strength of finished blocks, and the sound and heat insulation characteristics of finished building materials.
Manufacturing consists of the following stages:
- grinding sand (to obtain the best level of hardness - together with cement);
- adding other components (10-20% lime, water);
- pouring the resulting mixture into the pool, and from it using a pump into a concrete mixer;
- filling special forms with a solution placed in an autoclave.
Processing blocks in an autoclave for 14 hours increases their strength by 2 times.
Making the mixture
Foam concrete mixture is made in 2 ways:
- With classical technology, the foam mixture is prepared separately and then added to the concrete solution, the components are mixed, and then sent through pipelines into prepared forms.
- When using barotechnology, all components of the mixture enter a sealed mixer, inside of which air is pumped by a compressor, the components are mixed in the process and are saturated with oxygen. The finished mixture is fed under pressure into injection molds, in which it swells due to pressure changes.
In both cases, additional components and plasticizers can be added to the solution.
Molding
To obtain foam blocks of the required shape, molding is used, which is carried out by:
- pouring the solution into molds of the required size;
- cuttings from solid monolithic blocks.
Manufacturing process
Drying
When producing foam blocks using the injection molding method, the finished product is dried:
- in a natural way (the blocks are dried in molds for about 10 hours, then without them);
- thermally using a steaming chamber (a few hours are enough for the foam blocks to reach 75% of the design strength).
The production of foam blocks using cutting technology allows the use of only natural drying. The process takes from 4 to 14 hours, the drying time is influenced by factors such as the cutting method used, cutting elements, and additives included in the blocks that accelerate the hardening process.
AeroStone
Russia's largest enterprise for the production of aerated concrete, which can safely be called the best manufacturer of foam blocks . Production capacities make it possible to supply large construction projects and even more than one, since the daily production rate is an impressive 1,500 cubic meters. meters of initial construction raw materials. This amounts to 500 thousand cubic meters per year, which is impressive and makes the company a leading enterprise. The plant is equipped with the latest technology with the latest modern German Masa-Henke equipment and undergoes quality control of all products by specialists from Germany.
The plant is located in close proximity to Moscow and allows it to simultaneously meet the needs of the mass of developers who carry out their construction in this region. At the same time, the enterprise’s capacities and logistics center work with the regions and can easily cope with all the required volumes, if necessary, increasing daily production. Gas block products have excellent frost resistance, resistance to abrasion and cracking, and are also lightweight.
- Country of origin – Russia
- Company address: Moscow region, Dmitrovsky district, Selevkino village, 195
- Manufacturer's website - https://www.aerostone.ru
Bonolit
Another largest company for the production of aerated concrete, which carries out very large production volumes, reaching up to 650 thousand cubic meters. meters per year. Which is one of the largest volumes in Russia. All foam blocks are produced on the best modern and technically advanced production line HESS AAC Systems BV . The company has its own school where you can get training in building houses from Bonolit products and gain the most advanced knowledge in this field. Using this knowledge, it will be possible to build a house using special technology that will allow it to stand for 100 years.
The manufacturer works with all clients, but for privileged customers there is a Bonolit Club , which unites all corporate clients and helps to better ensure work with such a volume and level of client. The plant produces various types of blocks, which include ordinary blocks for walls with a width of 200 to 500 mm or U-shaped blocks for the manufacture of window or door lintels. Each client is valuable to the company and will receive comprehensive information of interest about any production and other issues regarding delivery or payment.
- Country of origin – Russia
- Company address: Moscow region, Staraya Kupavna, st. Concrete, 1
- Manufacturer's website - https://www.bonolit.ru
Necessary equipment
When choosing equipment for the production of foam blocks, it is necessary to proceed from the technology by which the building materials will be produced.
Using ready-made foam involves purchasing a special machine that allows you to mix the components and prepare the solution. Domestic equipment costs about 210 thousand - 250 thousand rubles. Foreign installations – from 2 million rubles or more.
Just starting the production of foam blocks, you can get by with domestic models, and after the business becomes profitable, you can purchase more powerful foreign equipment.
The cost of molds for pouring cement mortar is influenced by the material of their manufacture, volume, etc. One compartment costs about 4 thousand rubles, to start production you need at least 15 compartments.
Drying of foam blocks is carried out using a compressor. Production is impossible without a special pump that pours the solution into molds.
GRAS
GRAS is a group of companies that has a full cycle of production, construction and distribution of its products . The company has completed many major construction projects, which were implemented very successfully. The company's name is widely known and respected in the Russian foam block market. The company easily implements the construction of housing of any class, be it an ordinary cottage or more daring projects such as global construction projects with apartment buildings such as the elite complex “Alexandrisky Mayak” or huge office buildings. The company was founded quite recently in 2005, but has managed to become a leader among the best manufacturers of foam blocks.
The corporation has several factories in other regions of Russia, for example, GRAS-Saratov or GRAS-Kaluga, which were created to meet construction demands in all regions of Russia. The company can boast of such projects as the cottage community "Zemlyanichnaya Polyana" , the residential complex "New Alexandria" or the latest project of the MPI residential complex on Ostashkovskaya Street. Such volumes allow us to provide only the most modern production facilities.
- Country of origin – Russia
- Company address: Moscow, Kyiv metro station, st. Kyiv 7, entrance No. 7, 4th floor
- Manufacturer's website - https://www.gras-group.ru
Ytong
The name Ytong is the same name for cellular concrete, which was started to be produced in 1940 by Karl August Karlen. This building material became the ancestor of autoclaved aerated concrete or foam block. The German company has powerful production lines in Russia and is a leading enterprise not only in the domestic market, but also at the international level. Modern technologies and German meticulousness give high quality to all the manufacturer’s products, which easily compete with Russian manufacturers, far surpassing them in strength and quality.
The Russian Ytong plant was launched quite recently in 2007 and quickly took a leading position, which is not surprising, since it is a worldwide name . Not a single large construction project in Moscow and beyond could do without products and foam blocks from this manufacturer.
- Country of origin – Germany
- Company address: Moscow, st. Rabochaya, 93, building 2, entrance 3
- Manufacturer's website - https://www.ytong.ru
