Do-it-yourself excellent floors made of shavings and sawdust concrete of arbolite

Mixing

One of the most laborious stages in the production of sawdust concrete (even a novice builder can make blocks with his own hands) is mixing, therefore it is recommended to use a concrete mixer or at least a mortar mixer. This will make the mixing procedure not only more comfortable, but also of higher quality.

Before pouring the dried sawdust into a concrete mixer, they must be sieved through a sieve with a 1 cm cell side. Then you can mix the sawdust with cement. Only after that, clay or lime dough, prepared in advance, is added to the mixture. All components must be thoroughly mixed and diluted with water. Water should be added in small portions.

If the mixing of sawdust concrete is done properly, then when squeezed in a fist, the mixture will form a plastic lump, on which, in the absence of water droplets, dents from fingers will be visible. This is considered the main indicator of a properly prepared mixture.

Wood concrete manufacturing technology

Such material as wood concrete is easy to make on your own on your site. To do this, you will need inventory:

• concrete mixer;
• forms for pouring the finished mixture.

You will also need:

• sawdust;
• cement;
• lime or clay;
• sand.

Composition of materials for wood concrete

Since wood concrete belongs to sawdust concrete, then it becomes clear that it includes cement of different brands. And also to increase the strength of the wood concrete material, even cement with the best characteristics is used.

Shavings and sawdust are added to the concrete. When such material is not enough, then it is filled with waste from needles, foliage or bark, only in a concentration of no more than five percent of the total composition of the filler.

The amount of material for the formation of wood concrete

The finished form of wood concrete should be 5 × 25 mm. For this, the entire organic composition is passed to a crusher. Further, such a crushed composition is added to the cement mixture.

Previously, in factories, special chemicals are added to organic matter to neutralize sugar. This is due to the fact that sugar impairs the strength of wood concrete and must be removed.

Manufacturing steps

1. Sifting sawdust with a mesh sieve - 1 × 1 cm.
2. Placement of sawdust and sand in a concrete mixer.
3. The composition is mixed in a concrete mixer.
4. And how much cement is needed in arbolite, is determined by its brand, is supplied together with lime.
5. Mixed in a concrete mixer.
6. The composition is poured into molds of 15 cm each layer.

Within 3 months, the wood concrete becomes durable.

So, how much cement is in arbolite:

• in the 5th grade of wood concrete there is 1 / M 400 cement;
• in the 10th grade of wood concrete there is 1 / M 400 cement;
• in the 15th grade of wood concrete there is 1 / M 400 cement;
• in the 25th grade of wood concrete there is 1 / M 400 cement.

If there is the right amount of cement, a light-weight material is created with a strength of 400-850 kg / m 2 and is fire-resistant at a temperature of 1000 C.

Construction technology

Building a house from logs and cement is quite simple. First, they make the foundation and the basement part - according to the same rules as for an ordinary wooden building from a construction bar.

How is the construction of a house from chocks and cement carried out:

• A layer of waterproofing is laid on the basement.
• A solution is placed on top of the waterproofing in two strips 6-7 centimeters wide. The distance between the outer edges of the strips should be equal to the thickness of the wall (the length of the logs), the height of the layer is 3 centimeters. The gap between the strips of the solution is filled with a mixture of lime and sawdust, then the logs of the first row are placed on the solution (they need to be shaken and pressed a little).The gap between adjacent logs should be equal to 3 centimeters.

• The subsequent rows of chocks are laid in the same way.
• While the mortar has not yet set, the seams of the masonry are embroidered outside and inside the house, everything is leveled, the solution is compacted in the gaps between the logs. The seams should be about 5 millimeters deep.
• Creation of openings for doors and windows at the desired height, their installation is done later.
• To support the attic floor beams, roof rafters, a Mauerlat is laid along the top of the walls. Moreover, the bars of the frame are attached to the wall with wire ties: the end of the wire must be twisted around the chocks in the thickness of the upper part of the wall, the second must be fixed on the roof rafter. The roof can be made from bitumen shingles, wood planks, and other materials.

Walls can be sheathed or finished with various materials inside and out, similar to a conventional wooden house.

If the house is being built in a cold climate, the logs should be laid in 2 layers with air pockets inside, which are filled with insulation (preferably ecowool). Layers of masonry are tied together with long logs running along the entire thickness of the wall.

The technology of building houses from logs has been used for a long time. Today, such structures can be seen in Yakutia, where they serve with dignity at temperatures below -50 degrees and perfectly keep the indoor climate even with average daily fluctuations of 40-42 degrees.

Composition

The main component of building material is sand, as well as cement and shavings (chips). Cement affects strength, workability and some other performance characteristics. The cement grade used to create the blocks must be at least M400.

The increased content of sawdust enhances the sound-absorbing and heat-insulating performance of wood concrete blocks. The chips must be thoroughly dried before use.

For example, a component that increases the fire resistance of the material is almost invariably used. In addition, a substance that repels rodents and other pests can be used.

Varieties of blocks, their qualities and characteristics

Aerated concrete is concrete with a cellular structure. It is made from cement with the addition of quartz sand and foaming agents. The finished mixture is distributed into molds and water is added. In the course of the reaction, the mass foams, filling the mold.

To make the material stronger, the finished blocks are steam-treated in autoclaves. As a result of exposure to high pressure, quartz sand changes its structure, becoming stronger. In other words, a foam block is a lightweight artificial stone with great strength.

What blocks are better for building a bath when erecting load-bearing walls and partitions? Of course, this is autoclaved aerated concrete (read: "How to build a bath from aerated concrete with your own hands - step by step instructions"). For insulation, you can also use non-autoclave, since he is cheaper, but its durability is not so high.

Aerated concrete blocks are found in various densities:

• 0.3-0.5 t / m3 - used for thermal insulation;
• 0.5-1.2 t / m3 - suitable for building walls.

For the construction of small buildings, aerated concrete of the D500 brand with a density of 0.5 t / m3 is suitable. It can also be used to lay out boxes and partitions, and its price is not as high as that of high density brands. When building a bath from a foam block or a gas block, in order to save them, they are laid on the edge, while the wall will turn out to be about 200 mm thick (in more detail: "Which project of a foam block bath to choose - from planning to construction"). This will be enough, because the block perfectly retains heat, and the walls themselves will still be insulated.

Aerated concrete is notable for the fact that it has a small mass, it is easy to process (a hacksaw is suitable for cutting, and you can make a hole with a simple drill), it is not flammable, and over time it only becomes stronger.Of the minuses, it can be noted that it is highly hygroscopic (for low-quality material) and a considerable cost.

A variety of aerated concrete - gas silicate - is distinguished by an astringent additive. For aerated concrete, this is cement - up to 60%, and for gas silicate it is lime - 24% and 62% of quartz sand. In addition, gas silicate is produced only in autoclaves. Materials vary in color and hygroscopicity.

Gas silicate is white in color, it is able to strongly absorb moisture, from which it is subject to destruction. Aerated concrete, on the contrary, allows moisture to pass through, keeping the room at a normal level of humidity. That is, when choosing between these two materials, unambiguously, aerated concrete will be the best choice.

Foam concrete is one of the types of aerated concrete. For its production, a composition of cement, sand and water is used, to which foam is added from a foam generator. The technology for the manufacture of foam blocks is quite simple, so that the production process is possible privately.

This, in turn, generates a number of dangers for the end user, since there is a high chance of buying poor quality material at an inappropriate price. Over time, such material will surely begin to deteriorate and collapse.

The positive side of foam concrete can be considered its lower cost compared to aerated concrete and higher levels of hygro resistance.

Sawdust can serve as a filler in the production of building blocks, while this material is called sawdust concrete. It is easy to cut and drill, and its thermal conductivity is twice that of a brick. In addition, sawdust concrete is an environmentally friendly and non-combustible material, and it has a small mass.

Among the minuses, one can single out the fact that the material is afraid of moisture, but this is partially eliminated by pretreating the sawdust with moisture-repellent mixtures or by waterproofing the walls.

Expanded clay concrete is another type of building blocks, which, by and large, replaced the cinder block. In this case, expanded clay acts as a filler (burnt and foamed clay). Expanded clay concrete is absolutely harmless, maximally hygroscopic and has high thermal insulation properties.

Blocks made of such material have a relatively low mass. A bath from it turns out to be more practical than from foam concrete or aerated concrete, since expanded clay concrete requires less thermal insulation materials, and it is easier to mount fasteners. Bath insulation is also practiced. from expanded clay concrete blocks from the inside, which is very effective.

The thermal insulation qualities of expanded clay concrete are determined by the fractions of the filling composition - the larger they are, the higher these qualities, but the density decreases. In the process of building a bath from such a material, it is best to carry out insulation from the inside.

Production of bricks from sawdust on an industrial scale

In the event that you want to put the production of bricks from sawdust and cement on stream, open your own business, then first of all you should draw up a business plan.

First of all, calculate the cost of purchasing equipment.

To do this, you will need:

1. Concrete mixer;
2. Crusher for grinding sawdust and wood shavings;
3. Scales for weighing components;
4. Molding dispensers;
5. Vibrating table;
6. Drying chamber;
7. Warehouses for storing raw materials and finished products;
8. A specially equipped, covered area or workshop for the production of bricks or insulation blocks.

If you don't want production to depend on weather conditions, then it is best to think about a large, spacious, heated room. In which it will be possible to work all year round.

The second, no less important aspect is to think in advance where you will start selling finished products.

Also, you can offer your products to construction firms, organizations, and so on.

Having learned the market purchase prices, and having roughly determined the volume of production, you can calculate the terms for which your investment will pay off.

Since the production of bricks from sawdust and cement does not require too much investment. Then, if there is a sales market, you can reach a net profit in about three months.

Sizes of products made of sawdust and cement

Factory sizes of standard sawdust and cement bricks are equal to the ratio:

• Height - 20 or 25 centimeters;
• Width - 20 or 30 centimeters;
• Length - 40 or 50 centimeters.

But, other ratios are allowed, especially if you are building for yourself. If you wish, you can make the blocks wider than 30 centimeters.

Or make bricks taller than 20 centimeters. You just need to take into account that in this case the blocks will be heavier, and you need to spend more effort on their transportation to the object.

The dimensions of the insulation panels can also vary significantly in size. Many manufacturers make panels according to their time-tested dimensions.

On average, you can specify the following sizes:

1. For floor insulation - 82 cm x 62 cm x 8 cm;
2. For wall insulation - 82 cm x 62 cm x 10 cm.

As part of insulation boards: 90% pine chips and 10% cement M500 + mineralizers.

Production

Dried wood, best of all softwood, is passed through a crusher and then enters the drum of a concrete mixer.

Water, aluminum sulfate, cement are mixed separately. Dry sawdust is poured with this solution and mixed for five minutes.

After that, the finished mixture is placed in molds lubricated with used machine oil. It is compacted by vibration and force. It is pressed and dried.

Dries within 12 - 18 hours in a drying chamber.

The less cement you put in percentage, the more the product will keep warm. However, this decreases its strength.

Conversely, the more cement, the denser and stronger the product, but, at the same time, the thermal conductivity increases.

Material consumption, proportions

The selection of the composition for the manufacture of wood concrete is carried out by calculation and experimental method. Much depends on humidity, quality of raw materials and wood species.

Also, on what brand of product you want to get at the exit. For the initial, trial batch, according to GOST, it is recommended to use the proportions specified in the instructions for the manufacture of wood concrete products - CH549-82.

In special tables which set out the recommended proportions of all components for the first batch.

Video on the topic of making bricks from sawdust, an example of a small business.

Facing brick or clinker tiles, whichever is better;

Refractory bricks are irreplaceable;

Solid brick: definition, types, production;

Silicate brick, advantages and disadvantages, application;

What is fireclay brick.

Sawdust blocks: characteristics

Sawdust concrete assumes certain properties and requirements for use in construction. So, to prevent moisture ingress, the basement of the house is usually made of concrete or brick with a height of at least 50 centimeters from the blind area. Also, the departure of the cornices outside the border of the facade walls is made at least 50 centimeters with the installation of a system for removing melt and storm water.

The thickness of the seams between the blocks is about 10-15 millimeters, often the blocks are used only for laying the insulating inner layer.

If cement-particle blocks (slabs) are used to create window / door lintels, they must be reinforced. As for the rest of the requirements, they are all due to the characteristics of the material.

Blocks composition

The main components of sawdust concrete:

Sand - increases strength, but reduces the properties of thermal insulation (therefore, it is important to choose the optimal proportion)
Portland cement - minimum grade M400
Wood shavings (chips) - enhances sound / thermal insulation, dry before use
Special additives - for fire resistance, rodent impregnation, etc.

Components

Waste of various types of wood can be used in the production of sawdust concrete: fir, pine, poplar, spruce, beech, birch, ash, hornbeam, oak, larch. But coniferous wood chips are considered the best choice, since the concentration of resin is increased in it, which protects against rot.

Accelerated hardening is characteristic of pine - blocks can be used in construction as early as 40 days after casting into molds. Oak chips and larch extend the curing period - they require settling for at least 100 days.

In order to increase strength, resistance to fire and reduce the ability to absorb moisture, wood components are prepared in a special way: soaked in milk of lime, dried (forced / naturally), soaked in water glass mixed with water (1 part glass and 7 parts water). To ensure the homogeneity of the material, the chips are passed through a sieve with cells of 10-20 millimeters.

Proportions

The ratio of materials in the composition directly affects the density and other characteristics. Sawdust concrete is of different classes, which determine the properties and proportions. So, M5 / 10 classes are used for insulation and reconstruction work, M15 / 20 - for the construction of internal / external walls.

Proportions of materials for 1 m3 of sawdust concrete:

• 5 grade (density about 500 kg / m3) - 50 kg each of cement and sand, 200 kg each of lime and sawdust
• 10 grade (650 kg / m3) - 100 kg of cement, 200 kg of sand, 150 kg of lime and 200 kg of sawdust
• 15 grade (800 kg / m3) - 150 kg of cement, 350 kg of sand, 100 kg of lime and 200 kg of sawdust
• 20 grade (density 950 kg / m3) - 200 kg of cement, 500 kg of sand, 50 kg of lime, 200 kg of sawdust

Mixing components

The mixing process is as follows: measure all materials, mix dry sand and cement, add lime and sawdust, mix again thoroughly, pour in water in portions, achieving the desired consistency of the solution.

First, it is advisable to make a test batch, check the mixture for elasticity: if the lump crumbles, you need to add water, if the water flows down, reduce the volume. A correctly mixed solution hardens within an hour.

Sawdust size

This parameter has little effect on the strength of the blocks, here the homogeneity of the material is more important than the value. Therefore, the sawdust is chosen such that all components are of the same size and make it possible to prepare a homogeneous mixture.

Chips from the sawmill are suitable - it does not matter, disc or belt. But do not take sawdust from calibration or cylindering machines, as they are heterogeneous in structure.

Product forming technology

Before the start of pouring, the inner surfaces of the mold are lubricated with grease, machine oil or a special separating solution. Next, a mixture of cement with sawdust and additives is loaded into the mold, layer by layer. Each next layer is rammed with a piece of a bar covered with galvanized steel or a mechanical vibratory rammer.

The filled and tamped forms are left for a day, after which the blocks are carefully removed, placed in a cool place and covered with plastic wrap. On hot days, to avoid drying out, the blocks are sprayed with water. After 14-20 days (subject to an ambient temperature of 20 degrees Celsius or more), the blocks are ready for use.

Features of the production of blocks from shavings and cement

• Before use, shavings and chips must be passed through a chipper and hammer crusher, and also sorted on a vibrating screen or through a hand sieve;
• The finished mass with additives should be thoroughly mixed with cement in a mechanical concrete mixer and only then fed into the prepared forms. The proportions of the components are different. In general, a recipe is recommended: 1 part of Portland cement, 6 parts of a mixture of shavings and chips, 2 parts of sand + additives;
• Manufacturing technology of a form or several forms.From edged boards and wooden bars, a frame with dimensions of 600x300x240 millimeters is knocked off or twisted (with self-tapping screws). Handles are nailed on opposite sides of the frame (bars 250x50x50 mm). To each form, from boards and bars, a pallet is knocked down or twisted. For the convenience of removing the block, the inner surface of the frame and pallet is upholstered with galvanized steel or linoleum.

Types of wood-cement materials

Depending on the added wood filler, wood-cement materials of various sizes and structure are obtained. The result is also influenced by the type of binder.

Among the many options, the following widely used types can be distinguished:

• arbolite;
• fibrolite;
• sawdust concrete;
• cement-bonded particle board;
• xylolite.

Arbolit

It is a material with a high content of wood chips, water, a binder - mainly Portland cement - and chemical additives for various purposes. For the manufacture of wastes of the wood industry from deciduous and coniferous species are used. An alternative is flax or hemp fire, chopped straw, crushed cotton, and similar raw materials.

It is divided into two main classes: construction and thermal insulation. In the second, the percentage of the wood component is increased, but the strength is reduced.

Arbolite is used to create products for any purpose:

• blocks for forcing external and internal walls;
• floor slabs;
• floors and coverings;
• large wall panels.

Fibrolite

This building material is produced in the form of boards based on chip waste and a binder. According to the parameters, the raw material for wood filler is shavings 35 cm long and more and 5 to 10 cm wide, ground into wool.

At the next stage, the wood filler is mineralized with potassium chloride, it is moistened with water in a certain proportion and mixed with cement mortar, and then pressed into plates under a pressure of 0.4 MPa. Then comes the heat treatment and drying of the finished products.

There are two types of material: heat-insulating and insulating-structural.

The characteristic properties of this material are:

• strong roughness - determines its high adhesion properties with finishing materials;
• fire safety - the material does not burn with an open flame;
• high thermal insulation performance - thermal conductivity is only 0.08-0.1 W / sq. m;
• ease of processing - cutting, drilling, hammering in dowels and nails is carried out without any problems;
• moisture absorption in the range from 35 to 45%;
• vulnerable to fungal mildew at humidity above 35%.

Sawdust concrete

This material is similar to wood concrete, but it does not have such strict criteria for wood filler. The material is so called due to its composition - it consists of sand, concrete and sawdust of different fractions. In addition, this material may contain lime and clay, and the percentage of sand may exceed that of wood concrete. Thus, at the same density, the strength of sawdust concrete is less.

As a result, the weight of the supporting structure made of sawdust concrete will be greater than that of wood concrete with the same class of structural strength - M. The thermal insulating properties of sawdust concrete are also inferior to wood concrete.

In addition, the strength of sawdust concrete is inferior to wood concrete, but significantly exceeds the strength of other porous block materials of non-wood origin.

Cement particle boards

Such a material belongs to a widespread type, made from a wood-shaving mixture mixed with water, cement and mineral additives, followed by dosing, molding, pressing and heat treatment.

The characteristic features of the material include:

• frost resistance;
• incombustibility;
• biological inertness.

The uniqueness from other wood-based materials lies in the high moisture resistance of the boards.The disadvantages of this material include a relatively large weight - 1.4 t / cu. m, which makes it harder to work with them above the first floor. The second disadvantage is weak elasticity, due to which, with a slight bending of the slab, it breaks. On the other hand, slabs are resistant to longitudinal deformation and are used to strengthen the frame.

Xylolite

Refers to sand materials based on magnesia binder and wood waste: sawdust and flour. The composition contains fine minerals: talc, marble flour and other ingredients, as well as alkaline pigments. During the production process, a high pressure (10 MPa) and a temperature of about 90 ° C are used, which provides special strength during hardening.

The characteristic features of xylene are:

• high compressive strength, depending on the specific type (from 5 to 50 MPa);
• excellent resistance to shock loads - the material is not chipped, but crushed;
• high noise and heat insulation properties;
• incombustible;
• frost-resistant;
• moisture resistant.

For information on how to make blocks of cement and sawdust with your own hands, see the next video.

Raw materials for the manufacture of sawdust concrete

In addition to sawdust, the material includes:

• lime;
• cement;
• sand;
• water.

Sometimes craftsmen improve this composition by adding clay to it. Because of this, the strength and thermal conductivity of houses built from sawdust concrete increases.

The density of the material depends on the amount of sand, cement and sawdust used. Sand plays an important role. The more it is, the denser the structure of sawdust concrete is. If it is less, the house increases the thermal conductivity.

It is worth considering that a certain amount of raw materials can provide frost resistance and water resistance of sawdust concrete. At the same time, reinforcement masonry is also protected, which, under the influence of moisture, corrodes and destroys its structure.

In the manufacture of sawdust concrete for construction, the following technical characteristics of houses are taken into account:

• the thickness of the walls of the future house;
• number of load-bearing walls;
• the number of interior partitions;
• number of storeys of the cottage.

Positive and negative characteristics

The advantages of block material made of sawdust (they are confirmed by numerous reviews given in the material about the pros and cons of wood concrete):

• easy to process - sawdust concrete can be cut with an ordinary hacksaw and drilled, just like aerated concrete or foam concrete;
• has good adhesion characteristics - when processing with adhesives, the topcoat is reliably fixed to it;
• good thermal insulation properties;
• low-combustible - with the correct manufacturing technology, sawdust concrete can withstand direct exposure to fire for about three hours (if the amount of sawdust does not exceed 50% of the total volume);
• environmentally friendly;
• soundproof;
• simple masonry;
• long service life.

Sawdust concrete acquires the property of fire resistance as a result of enveloping the sawdust with a cement-sand mixture. Compared to concrete with expanded polystyrene granules, sawdust blocks are more fireproof.

The disadvantages include a long curing time. After manufacturing, building blocks with a thickness of 20 cm are left for 3 months to fully harden. Only after this period you can start laying them. Sawdust concrete has poor water resistance. Therefore, after the construction of the house, a vapor barrier should be installed to protect it both from the inside and outside of the building.

How to do it yourself?

There are many technologies for making blocks from sawdust. Not only cement, but also gypsum or clay can be selected as a binder. But if the block material will be used for the construction of loaded structures (walls), then Portland cement is taken.To prepare the mortar on your own, it is recommended to use a concrete mixer, since a completely homogeneous consistency is required.

According to the technology established in accordance with GOST, in order to make high-quality blocks, it will be necessary to mix the components in the following proportions - 1 part of cement, 1 sawdust, 3 sand and 50% of the volume of binder water. Calcium chloride is taken 40 times less than the amount of cement powder. That is, 20 kg of M400 Portland cement will require 20 kg of sawdust, 59-60 kg of sand and 10 liters of water. Additionally, 0.5 kg of calcium chloride is poured. In percentage terms, sawdust should make up almost 55% of the total solution volume, sand - 26%, cement - about 12%, water - 7%.

Sand is used in medium or coarse size. At the same time, about 10% of fine fraction is added. Only clean water is poured in. Drinking or rainwater is best, the main thing is without impurities and dirt.

To make the blocks yourself, you will need forms in which the mixture will fit. It is recommended to make them collapsible, so that it is more convenient to pull out the finished material. It can be built from boards with a thickness of 20 mm. Inside, they are covered with sheets of steel so that moisture from the solution is not absorbed into the wooden case. In addition, thanks to the metal, the block material can be easily separated from the mold.

Manufacturing technology: sawdust is sieved through a sieve and mixed with Portland cement and sand. Water is gradually poured in. To check the quality, the solution is squeezed in a fist. It should crumple into a lump, water should not flow out. If droplets are visible, then it is not mixed up correctly. After preparation, the composition must be wasted within an hour and a half. The mixture is placed in a mold. Every 20 cm, it is rammed to compact and remove air. After filling, everything is left for 4 days. After that, it can be disassembled and folded block building material in a dry and ventilated room for further hardening.

Peculiarities

For wood concrete blocks, not sawdust with sand, but only chips are used; cement and various additives are also needed that improve other characteristics. Compared to sawdust concrete, this material has even better thermal insulation properties. It is just as lightweight, frost-resistant and non-combustible. The blocks are environmentally friendly, they are easy to cut and handle.

For self-production of such blocks, you will need forms. The solution is mixed in a concrete mixer. To make wood concrete blocks, the components are mixed in the following proportions: 3 parts of cement, 3 parts of wood chips and 4 parts of water. First, chips are poured into the concrete mixer and water is poured in (not all at once, only to a semi-liquid state). Liquid glass is added (1% of the total). After the consistency has become homogeneous, Portland cement M400 is poured in and the rest of the water is poured in.

Once the solution is thoroughly mixed, it is placed in a mold for wood concrete blocks. Every 15-20 cm the mixture is tamped. A day later, if the material has hardened, it is removed from the molds and left to cure. After 2-3 weeks, the blocks can be used.