Business plan for the production of building blocks - how to open the production of wood concrete, aerated concrete, wall and expanded clay building blocks

Elements of load-bearing structures made of aerated concrete are actively used in modern construction. Durable and lightweight blocks replace wood and brick where it is necessary to speed up the pace of project development or optimize the budget. A business plan for the production of blocks can be developed on the basis of initial knowledge of entrepreneurship and technology for manufacturing materials for load-bearing structures. Inexpensive equipment, easy-to-learn technology and quick payback are attracting more and more beginning entrepreneurs.

To open your own production you will need a business plan and some initial capital

Necessary documents for the production of building blocks

According to rough estimates, the cost of producing materials for load-bearing structures is about 500,000 rubles. In ready-made production, the expanded clay block is very cheap. At the same time, investments alone are not enough. When starting a business, it is necessary to take into account a number of legal issues, including the choice of the status of the future enterprise.

Working in a shadow business may bring the expected results, but the number of clients will be minimal. In addition, supervisory authorities may be interested in an illegal enterprise. Therefore, a business plan for the production of heating blocks must include a clear development concept, taking into account correct design in accordance with the current legislation of the Russian Federation.

Before starting a business, you need to complete the relevant documents

Considering the modest turnover at the development stage of the enterprise, you can opt for registration as an individual entrepreneur. These are the minimum costs for opening, designing and maintaining administrative and working resources. Of the two types of simplified tax system, the optimal one will be “Income minus expenses”, taxed at a rate of 15%. Considering that the business plan itself for the production of wall blocks will cost free, legal registration in general will require about 10,000 rubles.

What you will need:

Application for registration as an individual entrepreneur. If you don’t have time, you can send an application with attachments by mail;
Pay the state fee for starting a business (800 rubles);
Select the economic activity code corresponding to the line of business. Among the OKVED documents that the business plan for the production of wood concrete blocks will contain, group 23.61 and its subtypes should be indicated;
If the activity is planned to be developed with borrowed funds, care should be taken to draw up a business plan, as it will need to be submitted along with the loan application;
A lease agreement or document confirming ownership of real estate.

Since the business of producing building blocks is potentially harmful, you will need to obtain permits from regulatory authorities before starting the line. You will need to contact the Sanitary and Epidemiological Station, Rospotrebnadzor and the fire service with plans for the placement of equipment and storage locations for finished products.

Machine for the production of building elements

The principle of the design and operation of such equipment is quite simple - vibration. All building elements of this type in their original state have a dough-like consistency. This mixture is placed into block molds of the required size. Due to vibration, the composition is compacted and left to dry until it becomes hard.

All components for the production of building materials of this type are readily available. Parts for such a machine will also not be difficult to obtain. With a little effort, even a person who does not have special technical skills can make a device that will greatly facilitate the planned construction and significantly save financial costs.

The basis of the device for the production of building blocks is a vibrating table. It can be welded from corners or slats and sheets of metal at least 0.5 cm thick. The layer between them is steel springs standing vertically, which can be taken from the shock absorbers of a moped or motorcycle. The springs are permanently attached to the base at the corners. A sheet is placed on top and welded to them. A obviously unbalanced electric motor and devices for installing molds are attached to the top plate. The engine is fixed with bolts through rubber layers.

Business plan for cinder block production: requirements and choice of production site

The size of the area will be determined based on the arsenals of the selected equipment, its composition and individual units. If it is a fully automated block production line, it will occupy about 80 m². For semi-automatic production, which will be controlled by several operators, 50-60 m² will be enough.

When expanding production volumes, business will require new spaces. It will be possible to renegotiate the current lease agreement or move the construction of the blocks to a new larger premises

The production of building blocks from aerated concrete, wood concrete and other component compositions will require placement in an area that is safe for humans and the environment. A specialized industrial area or a vacant site outside the city is best suited.

It is immediately worth noting that the cost of equipment can vary in the range from 300 to 1200 thousand rubles. Therefore, the location for the production of aerated concrete blocks must be guarded or have means to restrict unauthorized access. Also, location outside the city is convenient for buyers, as they can easily drive up to pick up finished products.

If the business concept does not include strictly made-to-order work, it will be necessary to provide a storage area for manufactured blocks. Major renovations are not required at the location of the building block manufacturing business, however, cosmetic work will need to be taken care of during the presentation of the site. The equipment for a plant for the production of aerated concrete blocks is quite powerful, so there must be access to the power grid at the location. Also, at the place of work, it is necessary to ensure free supply of communications and drainage.

When choosing a construction site, you also need to pay attention to ensuring that the floor in the room is level, dry and clean.

Foam block production business plan: production equipment

Depending on the budget, a business owner can spend different amounts of money on the purchase of units. Optimal projects usually include an amount of 200,000 rubles. Everything will depend on whether a ready-made business line on building blocks will be purchased or a new conveyor will be assembled. In the second option, the entrepreneur will need to have good knowledge of the technological process. In this case, the profitability of producing heat blocks using our own assembly will be higher than those of a ready-made business.

What you need to buy:

Concrete mixer;
Vibrating table;
Form kits;
Forming pallets;
Pallets for receiving finished products - roller tables;
Peristaltic pump complete with foam generator and compressor.

This is what a standard concrete mixer looks like

Depending on the concept of concrete production, the owner may provide for the delivery and transportation of raw materials on their own. A used gazelle is quite suitable for these purposes. The cost of transport can approximately double the planned foam concrete production budget.

Preparation of a rigid concrete mixture from cement, aggregate and water

The solution is best prepared in a forced-type concrete mixer (i.e. with mixing blades).

From the assortment we offer, these are the mixer models Vibromaster RP-200 and Vibromaster SB-80. Gravity-type concrete mixers (“pears”) can be used, but high-quality mixing will not be achieved. You can also mix by hand, with a shovel in any container. However, preparing a hard mixture will require significant physical effort. The productivity of such mixing will be extremely low.

Depending on the filler used (expanded clay, sawdust, slag, sand), we obtain, respectively, a solution of future expanded clay concrete, sawdust concrete, slag concrete, sand concrete.

Building block manufacturing technology

Standard production of durable forms for load-bearing structures requires adherence to a certain sequence. Particular attention in manufacturing technology is paid to the composition of the components from which the blocks will be produced. Depending on the chosen modification, the use of the resulting materials at one or another stage of construction will be determined. Despite the fact that expanded clay blocks are in demand among consumers, the market can often experience a change in current trends. For this reason, it is advisable to master several recipes in production.

The following components are used as raw materials:

Cement. The basis of the block design. The business plan idea may include grade 400 cement. If you plan to switch to a lower quality, you will have to increase the amount of the main component and reduce the amount of other building materials;
Filler. Expanded clay, slag, crushed stone, and residues (waste) from woodworking industries can be used. Depending on the selected material, the name of the finished product is usually determined;
Plasticizers. To enhance the practical properties of the product, various additives are used in the production process, which make it possible to control the technical characteristics of load-bearing structures at the manufacturing stage;
Water.

The technology for manufacturing building blocks in private production comes down to preparing a dry mixture, mixing it with water and other additives, molding and drying the finished products.

The finished substance is fed into a vibrating machine to shrink the solution, otherwise the block will not have the required qualities. After this, due to the operation of a special pressing device, the solution will be squeezed into molds for further drying. As the pallets are filled, the next ones are fed until the batch is finished.

In the case of gradual development of a new direction, you can start with small expenses. At the first stage of creation, one vibrating machine will be enough, which will calm the solution, bringing it to the required condition. By contacting one of the local cement factories, you can order a whole machine of a ready-made mixture of cement and gypsum in the required quantity.

Vibratory pressing cycle

The vibrocompression cycle consists of the following stages:

Loading the solution into the machine mold (done manually)
Compaction in the mold using vibration and pressure (punch). Compaction in the mold under the influence of a vibrator usually takes 20-30 seconds. This time and quality of compaction depends only on the vibrator. On Vibromaster machines we use only real certified vibrators with high disturbing force. Therefore, the quality of cinder blocks and production speed are guaranteed.
The block is removed from the mold immediately after compaction. The block remains either on the pallet or directly on the ground (depending on the design of the machine). A rigid solution and high-quality compaction allow the resulting block not to crumble and keep its shape “on its own” and “not float” during drying. The block on a pallet can be immediately transferred to a rack for further drying and strengthening. Some models of Vibromaster vibrating machines provide for stripping the form directly at the drying site.

As a result, we get a molded wall building block. Again, depending on the composition, this could be:

expanded clay concrete block,
wood concrete block,
cinder block,
sand block.

Recruitment of employees

You can organize a business in the production of building blocks alone. It will be quite difficult to directly engage in the production of materials alone. Even a private small plant will require at least 2-3 people, so the business plan should include an expense item for wages and staff training. To work on semi-automatic equipment, short-term courses will be sufficient.

Scope of application, advantages and disadvantages

FBS blocks are used in the arrangement of:

prefabricated or prefabricated monolithic strip foundations;
basements;
retaining walls to strengthen the landscape;
premises for household and storage purposes.

The undoubted advantages of FBS blocks include:

high quality and strict compliance with the declared overall dimensions, and as a result, high reliability, since they are manufactured in a factory environment in compliance with all necessary requirements in relation to the material used and production technology;
long service life;
high moisture and frost resistance;
convenience and ease of installation, which significantly reduces the construction time of the foundation (after all the preparatory work is completed, the construction of the foundation usually requires only 3-4 days);
high compressive strength;
use of ordinary sand-cement mortar for masonry (that is, there is no need to purchase special expensive adhesives);
the ability to design foundations of various sizes, since the blocks have three varieties in length (often you can even do without the use of additional parts made from full-size elements during the construction process).

The disadvantages of such blocks include:

Experts recommend building foundations based on FBS only on dry and sufficiently strong soils. This significantly limits their scope of application.
The need to use special lifting equipment for installation (for information: the weight of one product, depending on the size and material of manufacture, ranges from 0.23 to 1.96 tons).
When using FBS blocks, the overall strength of the base is lower compared to, for example, a monolithic strip foundation.

Marketing and sales plan

When a location for a business has been chosen, equipment has been purchased and placed, and even the necessary components have been delivered, all that remains is to sell the finished product. It is not so easy to do this taking into account the current level of competition, however, given the existing promotion opportunities, it will be possible to sell a small batch within the first week.

Among the inexpensive and at the same time effective advertising tools is the placement of advertisements for the sale of small batches of blocks. The text may indicate the possibility of meeting the needs of construction projects for the construction of private houses and cottage groups. A good way to express yourself is through an electronic platform on the Internet. At first, it will be enough to create a business card website or landing page. If an entrepreneur is not very strong in these matters, he can turn to professionals or freelancers. The price of the service will be from 5000 rubles.

As a promotion in a phased concept, you can resort to free advertisements. Such services still work, especially in sections of regional newspapers. Of course, you will have to work hard on the advertising and promotion text: briefly talk about the production technology, available equipment, and the advantages of cooperation with this company. This is how you can achieve a quick return on investment.

Types of advertising that are still active today

While interest in the product is fueled by excellent quality and balanced prices, you can begin to increase production capacity. After testing the equipment, you can purchase an additional concrete mixer and prepare the mixtures yourself at your own factory. Processing of the next batch will be faster, and the product will already be within the average price offers in the niche. This is how you can at least achieve self-sufficiency or even make your first profit.