DIY polystyrene concrete blocks

Properties and purpose of polystyrene concrete

The main advantages of the material:

• Good strength, which is why load-bearing walls are erected from it.
• Fire resistance.
• Low moisture absorption, which will allow you to maintain low thermal conductivity;
• Resistance to subzero temperatures.
• Good adhesion to other building materials.
• Excellent elasticity.
• Ease of installation.
• Resistance to aggressive environment, solar radiation.

Material properties

Taking into account the purpose, the solution is used:

• To pull the floor or insulate the floors.
• To erect walls, blocks are made from the form of polystyrene concrete.
• It is possible to build a monolithic house from the material.

Such concrete will exert less stress on the base and other structural elements. You will not need to use waterproofing, which is used during the insulation of the coating with mineral wool.

Assigning material

What is needed to make a working solution

The composition of the mixture for polystyrene concrete, in addition to cement, includes granular polystyrene foam. Or foam balls. It has very high heat-saving properties. Replacing sand in a solution with it, you can get a material with good thermal insulation characteristics.

The enlarged fragment of the photo shows the structure of the material

They will be higher or lower, depending on what proportions of polystyrene concrete will be chosen. And this choice, in turn, is determined by the area of ​​application of the ready-made solution.

We will talk about this in more detail a little below, but for now, look at what the recipe of polystyrene concrete is, in what proportions all the components are taken for its preparation.

More about each component:

• If instead of M400 we take cement of a higher grade, then sand can be added to the solution in a ratio of 2: 1 (2 parts of cement and 1 part of sand).
• Expanded polystyrene can be bought in hardware stores, it is sold in plastic bags up to 1 cubic meter.

Filler for warm concrete

SDO is a special additive that entrains air into the mixture and forms air bubbles, the presence of which increases the heat-shielding properties of the material.

Liquid plasticizer Optiplast

Preparation of the working mixture

For self-preparation, you will need the following materials:

• Portland cement M400 or higher;
• expanded polystyrene granules with a diameter of 2 ... 4 mm, sold packed in large bags (it is recommended to purchase spherical granules, although they are more expensive than round ones);
• air-entraining additive SDO in the form of powder or concentrated solutions;
• pure water;
• plasticizing additives.

On sale are ready-made specially selected dry mixes with polymer additives for the convenience of laying solutions (Knauf-Ubo, Polybeton).

It is recommended to use D350 grade polystyrene concrete for flooring. To prepare 1 m3 of solution, you will need:

• cement - 290 kg;
• polystyrene - 1 m3;
• LMS in powder - 0.28 kg or 0.7 l of concentrate diluted in 3.5 l of water;
• water - 120 l;
• plasticizers.

When using ready-made mixtures, preparation is carried out in strict accordance with the manufacturer's instructions, which is found on each bag.

The process of self-cooking from individual components consists in the step-by-step performance of the following operations:

• filling granules into a container with a volume of ≥ 20 liters;
• addition of about 10% water;
• careful movement with a construction mixer or a drill with a whisk nozzle for 30 seconds;
• adding cement and 85% of the remaining water;
• mixing until the granules are completely coated with cement;
• dissolving the LMS in the remaining amount of water and adding it to the container;
• stirring until a thick, creamy consistency. To increase the convenience of laying, plasticizers are added.

Polystyrene concrete - technology, compositions, recipes

Proportions of ingredients and composition of polystyrene concrete

To ensure the required properties of the composite material, its composition must be observed. The following ingredients are used for the manufacture:

• Portland cement marked M400 and higher;
• fine grained quartz sand;
• special additives that promote the formation of air cells;
• modifiers that increase the adhesion of cement to polystyrene granules;
• water added during the manufacturing process to the required consistency.

By changing the ratio of ingredients, expanded polystyrene concrete with different specific gravity is obtained, which is distinguished by marking:

• to prepare a mixture of grade D200, three bags of the 400th Portland cement and 0.8 cubic meters of expanded polystyrene chips should be used. 10 buckets of water are gradually introduced into the composition, and all components are thoroughly mixed;
• a mixture marked D300, characterized by increased density, is prepared with a consumption of 250 kg of cement of the M400 brand, one cube of polystyrene granules with the introduction of 120–130 liters of water.

The density of the produced expanded polystyrene concrete is also determined by the size of polystyrene granules, on which strength and thermal insulation depend. With an increase in size, the specific gravity decreases, as well as the strength characteristics. The optimum size of polystyrene granules is 5 mm.

In order to obtain blocks that are close to the factory ones in terms of indicators from a bulk solution, a special installation is required

We make polystyrene foam blocks - what needs to be prepared

For self-preparation of lightweight concrete mortar, you must prepare:

• concrete mixer used when mixing increased volumes of mortar;
• trough for manual mixing;
• electric drill with stirring attachment;
• shovels, buckets for loading ingredients and ready-made solution;
• forms in which polystyrene blocks will be manufactured.

We independently produce polystyrene concrete - work technology

It is not difficult to make your own polystyrene concrete. The technology resembles the process of making other types of concrete solutions. Production of expanded polystyrene concrete solution consists in uniform mixing of components.

The prepared mixture is used as follows:

• poured into casting molds intended for the manufacture of blocks from foam and concrete;
• loaded into the frame formwork when pouring monolithic structures.

Technology for preparing a solution with polystyrene granules:

1. Stir Portland cement with sifted sand in a concrete mixer or bucket.
2. Fill in the sifted sand, gradually introduce polystyrene.
3. Stir the ingredients until smooth by adding water.
4. Introduce plasticizers and necessary additives.

When preparing the solution, it is necessary to ensure its uniform consistency.

We make polystyrene blocks - professional advice

Professional builders recommend:

• grind the foam yourself to get granules. This will reduce costs, since the finished polystyrene granules are expensive;
• perform a test batch before preparing a solution in large volumes. This will allow you to correct the recipe, to accurately determine the composition;
• use for the manufacture of Portland cement marked at least M400. It will provide the required strength of the composite.

Polystyrene concrete is a promising building material that is advisable to use when performing construction and thermal insulation measures. Blocks made of polystyrene and concrete have high performance properties and can be made in a domestic environment. Having decided to use purchased products, order them only from trusted manufacturers.

How to make polystyrene concrete with your own hands

Most are trying to reduce the cost of construction work by making their own polystyrene on site.The raw materials are cement, foam granules and water. Wood resin is added to the mass, entraining air in the composition. This prevents the mixture from stratifying. In order to carry out the work qualitatively, it is necessary to familiarize yourself with the production technology of polystyrene concrete.

Composition and proportions

The creation of blocks is similar to the production of other building mixtures: in such a situation, it is necessary to observe the recipe and technology for creating polystyrene concrete. It is required to take into account that the material, like other solutions, is produced under various brands. Experts make compositions with high levels of thermal insulation, but with insufficient strength. The process of making polystyrene concrete with your own hands depends on the purpose of the material.

Before starting work, you need to find out the proportions to create a high-quality composition. It is required that the manufacturing technology is followed, high-quality construction equipment is used.

The composition of the mixture

To prepare polystyrene yourself, you need to observe the ratio of the components of different brands:

• Recipe: 160 kg of cement, 1 cu. m of polystyrene, 100 l of water, 1 kg of wood resin.
• 160 kg of cement, 75 kg of alluvial sand, 9 kg of polystyrene, 5 kg of latex, 95 l of water are used.
• You will need 190 kg of cement, 110 kg of alluvial sand, 10 kg of polystyrene, 4 kg of latex, 115 liters of water.
• For production, you will need 215 kg of cement, 180 kg of alluvial sand, 11 kg of polystyrene, 5 kg of latex, 130 liters of water.

Equipment

The production of polystyrene concrete is carried out without using heavy equipment. To obtain a homogeneous composition, a concrete mixer is used. The shape for the blocks will be chosen for future use. Additional equipment required:

• Generator. Establish, if necessary, the manufacture of 20-25 cubes of the mixture. This will ensure an uninterrupted supply of solution to the place of pouring.
• Mobile installation. Special comfort and automation of work is achieved by using this technique. The disadvantage will be the overpriced price. Purchased by professional construction teams. It is rarely used for private needs.
• Even using special equipment, you will need to independently find out the proportions per 1 cubic meter. m of material.

Equipment

There is a modern technique that is used in construction. The use is justified only at large enterprises:

• Conveyor lines. Produce more than 100 cubic meters. m of material per day. Allows you to achieve the exact geometry of all blocks. At each production stage, the quality of the prepared material is checked.
• Stationary lines. They have a compact size and an adequate price. Installed in medium or small businesses.

Work order

You can buy ready-made polystyrene in any hardware store. But the mixture can be prepared by yourself. The technology is simple, does not require any special skills or mastery. The elements and additives to create the solution are simply mixed. DIY instructions for making polystyrene concrete:

• At the initial stage, the required volume of components is measured. The proportions are calculated in advance. Then the components are poured into the container, where the subsequent mixing is carried out.
• The mixture will be of good quality when it has a homogeneous structure.
• The subsequent formation of blocks is carried out in special containers. Before the start of construction work, the molds are lubricated with a special composition (it includes machine oil). In view of this, it will be possible to remove them without effort at the end of drying.
• The prepared solution is poured into molds. They will need to be properly rammed.
• For the final drying of the mixture, it is necessary that several days have passed. The period will depend on the temperature indicators of the external environment and the volume of liquid that enters the mixture.
• It is also possible to fill the array. To cut it, you need special equipment. This option is used if there is a fixed line.
• Drying will be the final stage.After several days, the finished blocks can be transferred to pallets. Storage periods are not limited. It is permissible to store them in a warehouse.

It is allowed to start construction work from finished blocks after a few weeks. During this time, they will become durable, the indicators will correspond to the branded ones.

Polystyrene production

Polystyrene concrete screed device

Scope of work:

1. Surface preparation. The installation of floors is carried out after the complete completion of all construction, sanitary, electrical and finishing works.
   • the base is leveled with the cutting of all protrusions, filling of depressions, cracks and cracks with cement mortar of grade ≥ M100, leveling control using a laser level;
2. garbage collection;
3. dedusting the base.
4. pasting walls around the entire perimeter and existing columns with damper tape to the height of the screed;
5. installation of lighthouses from wooden bars, plastic or metal profiles. You can use screws screwed into the ceiling with plastic dowels.
6. Preparation of the solution in small portions.
7. The technology of polystyrene concrete screed is practically no different from the device of conventional cement-sand screeds. Sequence of execution:
   • moistening the surface with cement milk or ordinary water, the formation of puddles is unacceptable;
8. the layout of the mixture is slightly higher than the beacons. The recommended screed layer is 4 ... 5 cm. There should be no drafts in the room that prevent high-quality, without cracking, drying of the mortar;
9. distribution of the mixture using a rule or a wide spatula with alignment along the beacons. For compaction, you can perform a light slap with a rule. Work starts from the far corners, moving towards the front door to the room. Simultaneously with the smoothing of the solution, the screed is covered with a plastic film, for which, after laying in small sections, the roll with the film is rolled towards itself;
10. after 24 hours, the beacons are dismantled and the resulting recesses are filled with polystyrene concrete mortar, the use of cement-sand mixtures is unacceptable;
11. to strengthen the coating, you can perform reinforcement with steel meshes, with laying at a distance of 1/3 of the screed height from the floor;
12. with a room area ≥ 30 sq. m, expansion joints are arranged, with a smaller seam arranged near the door sills. Joints with a depth of 2/3 of the screed thickness and a thickness of ≥ 3 mm can be made directly during pouring.
13. The screed covered with plastic wrap is left to gain strength for 5 days. To remove excess moisture from the coating, it is left to dry without shelter for two to three weeks, depending on the thickness of the screed.
14. If necessary, the final leveling of the surface with cement mortar is performed, followed by grinding with grinders. Self-leveling mixtures can be used.

Do-it-yourself polystyrene concrete flooring, made in compliance with the correct proportions when preparing the solution and strict adherence to the recommendations set out above, guarantees the construction of a strong and durable rough floor covering without the involvement of expensive craftsmen.

External finishing

Manufacturing methods

The owners of country houses try to do all the work on the site themselves. This is one way to reduce construction costs and gain work experience. For the production of polystyrene concrete with your own hands, you will need a small set:

• A crumb of polystyrene. Strength and ability to retain heat will depend on its fraction.
• Cement. The strength of the finished material in bending or in compression will depend on its brand.
• Quartz sand.

An optional addition to the mixture is a plasticizer. With its presence, polystyrene concrete acquires plasticity. This allows it to remain intact during transport, hardening, drying and stacking.

Polystyrene concrete production

How to make polystyrene concrete with your own hands

Styrofoam can be made by yourself. Self-production creates building materials with the required properties.

Before the start of production, the necessary proportions of raw materials are calculated to give the finished product the necessary characteristics. Classic crafting elements:

• Cement of the M400 brand. When using a product of a higher grade, sand can be added to the mixture, by volume not exceeding half the volume of cement.
• A filler for concrete, expanded polystyrene with a volume of 1 m3 or more can be purchased at a hardware store.
• Plasticizer. You can use a special material, or you can replace it with liquid soap. The special plasticizer is added according to the instructions on the package, and the detergent is added in the amount of 20 ml per 10 liters.
• In order for polystyrene concrete to acquire the properties of protection from cold, it is necessary to add SDO (a substance that entrains air into the mass).

Production of polystyrene concrete

To create a high-quality mass for the manufacture of polystyrene concrete, it is necessary to use a concrete mixer. Polystyrene is poured into it, after which a plasticizer or soap solution dissolved in water is poured. When the water is evenly distributed over the mass, it is necessary to pour cement into the drum and pour water. After that, a water-entraining additive is added. And the mass is mixed for 2-3 minutes.

Laying homemade polystyrene concrete

Cons of homemade blocks

Polystyrene concrete is used similarly to cement mortar or in the form of ready-made blocks. In the first case, the material can be used to insulate the horizontal parts of the structure, and in the second, walls and other structures can be created. It is possible to organize the production of blocks if there are molds of the required size and a concrete mixer. But homemade building materials will have several disadvantages:

• The speed of erection of structures is significantly reduced;
• Due to the lack of production control, it is never known exactly what properties the blocks will have;
• The density of homemade polystyrene concrete will be low.
• The blocks will have uneven edges, which will increase the consumption of the masonry mixture.
• The lack of control over the consumption of different types of raw materials will lead to the production of materials of different quality.

DIY polystyrene concrete has its pros and cons. It is advisable to use it in the construction of structures that do not require great strength. These are low-rise buildings, outbuildings, cattle pens, garages.

Polystyrene concrete blocks

Advantages

allows you to create a coating with low thermal conductivity, so additional insulation is not required. In addition, the use of this composition for the screed allows to reduce the load on the base, because it is relatively lightweight.

The advantages of screeds made of expanded polystyrene concrete also include:

• durability;
• filling all cracks;
• good sound insulation;
• environmental friendliness;
• ease of installation.

Such a coating is highly resistant to rodents. Insulation cake made of sheet polystyrene often becomes a home for rats and mice, but if this material is presented in the form of granules covered with concrete mortar, it is reliably protected from rodents.

The hardened material has low vapor permeability, therefore, during its installation, there is no need to lay a vapor barrier film. Another advantage of this composition is incombustibility. Polystyrene granules in a concrete solution are resistant to even an open flame.

In addition, when arranging such a screed, there is no need to install additional waterproofing. The screed spreads well, so it fills in all the irregularities. Such a coating is more susceptible to mechanical stress than a concrete screed when it becomes necessary to repair utilities.Another advantage of this coating is the low cost of the components required to create the solution.

Disadvantages of polystyrene-based concrete, surface strengthening

There is one minus, but in some situations it plays an essential role. No matter what the proponents of polystyrene concrete may say, the compressive strength of the material is not very good. The same goes for abrasion resistance. Therefore, surfaces need protection and strengthening. When it comes to the walls of a building, in any case, a finishing layer or cladding is assumed, both outside and inside.

Expanded polystyrene can be used for pouring only in residential and public premises.

As for the subfloor. Expanded polystyrene can be used for filling only in residential and public buildings. For technical buildings, especially outdoor work, the material is not suitable. Even inside buildings, it is worth considering additional reinforcement of the top layer, or topping.

If we are talking about a public building with high traffic, respectively, the load on the floor surface, topping is made with special ready-made mixtures intended for these purposes. When a do-it-yourself screed is made for further laying of linoleum, laminate or parquet in living rooms, after pouring and partial setting of polystyrene concrete, it is enough to make an iron grind, which will give two positive points:

• strengthening of lightweight concrete;
• final leveling of the surface that meets the requirements for laying modern floor coverings.

Do-it-yourself topping mixture is very simple to prepare. Three parts of sifted river or washed sand and a part of Portland cement M 400 are taken. A solution is prepared with a consistency slightly thinner than for masonry. The prepared mortar is applied to the surface of the subfloor, leveled and rubbed with a plaster float. The grind layer is laid flat. Such a strengthening is quite enough for living rooms.

Cooking Steps Guide

Before you start making polystyrene concrete with your own hands, you need to accurately calculate the grade of concrete... Since it is on her that the maximum load that he can withstand depends. Blocks with a minimum strength are used only for thermal insulation purposes, and with increased strength for the construction of load-bearing structures.

For their production, you will need cement powder, polystyrene granules, surfactants and water. The proportions of the components directly depend on the purpose of the material. If you need the D200 brand, you will need to mix everything in the following ratio: 16 kg of M400 cement powder, 0.1 kg of surfactants and 9 liters of water.

To obtain D500, the components are mixed in a different proportion: 4.1 kg of cement, 0.08 kg of surfactants and 15 liters of water. The greater the proportion of cement in the composition, the higher its strength characteristics, but the lower the thermal insulation properties.

The presence of surface-active additives is mandatory, since they contribute to the uniform distribution of granules throughout the volume of the mixture and enveloping them with cement. To reduce the cost of cement and compact the solution, sand can be poured into it, but no more than 15% of the total volume of cement powder. If a conventional detergent is used instead of PAD, then 0.05 l is enough for 10 liters of water.

As surface-active additives used wood soap resin, detergent (for dishes, shampoo) or plasticizers. They are used in a ratio of 2% of the total volume of cement powder. The less cement, the more they need to be injected. Before adding plasticizers, you should study their instructions, since some of them must be diluted with water in advance, while others are immediately poured into the solution when kneading. PAD not only contribute to the uniform distribution of cement throughout the mixture, but also reduce the risk of cracking of the material.

In order for polystyrene concrete to obtain the best quality, it is necessary to observe the ratio of the components and the sequence of their introduction. If you plan to make blocks, then the molds are built first. They can be made from plywood or boards. If the base on which the forms will stand is even, then it is not necessary to equip the bottom in them.

Step-by-step instruction:

1. Cement and water are poured into a container or concrete mixer, after which everything is mixed until a homogeneous consistency.
2. Sifted sand is poured into the mixture.
3. Polystyrene granules are added, but not the entire volume at once, but only a part. As soon as the solution is mixed until smooth, pour out the next part of the granules.
4. Surfactant or detergent is poured in.

If blocks are made in molds, then they are left to harden for 1-3 days. The setting time depends on the room temperature and humidity. After being pulled out of the molds, they are left to gain strength for 2 weeks, then you can start laying them. If polystyrene concrete is produced in winter, then after pouring the solution into the formwork, it must be left for at least a week.

Helpful hints

1. In order for the structure to serve as long as possible, it is advised to close it with finishing materials to protect it from external influences (precipitation, dust), for example, plaster.

2. When adding water while mixing, it should be borne in mind that the mixture should not be too liquid and not dry. The ratio can be selected by trial and error on a small volume. If there is an excess amount of water, then the strength indicator of the blocks will deteriorate, and if it is insufficient, then cracks will appear in them after drying.

3. For mixing it is recommended to purchase only high-quality polystyrene and fillers. If you use a plasticizer of an unknown brand, then the indicators of frost resistance and moisture resistance may deteriorate significantly.

4. For masonry, a special adhesive is used, but not a cement-sand mortar. You need to breed it only according to the guide indicated on it. Then the seams will turn out to be thin and the likelihood of cold bridges will decrease.

5. To check the quality and correctness of the selected ratio, it is advised to make several blocks in advance and wait until they fully set their strength. When sawing, high-quality material will not crumble and collapse under the weight, and will also withstand constant heating for an hour and a half.

6. The main disadvantage is the high price. Most often, blocks are produced with dimensions of 60x30x38 cm (length, width, height).

Properties and purpose

The characteristics of polystyrene concrete take into account its lightness and practicality. Such a composite material is produced using a simple technology with minimal financial investment.

Specifications

Polystyrene concrete belongs to the group of composite building materials based on Portland cement or its varieties, silica filler, and also a porous component.

The manufacturing process provides for an even connection of raw materials, including:

1. Cement mixture.
2. Sand.
3. Water.
4. Granular polystyrene.

The mortar is placed into prepared molds or formwork at the construction site. To create quality material, you can use simple mixers.

The main properties of polystyrene concrete include:

1. Long service life - more than 100 years.
2. Compliance with environmental safety standards.
3. High vapor permeability.
4. Ignition resistance.
5. High moisture and frost-resistant properties.
6. Good noise insulation parameters.

The performance list is as follows:

1. Manufacturability - due to the low weight and correct geometry of the blocks, it is quite simple and quick to create walls and ceilings on their basis.
2. Thermal Insulation - A 30 cm thick wall structure can hold as much heat as a 180 cm brick wall.Thermal conductivity values ​​vary from 0.7 to 0.1 W / mS. This helps to reduce the cost of thermal energy by 5 times.
3. Water vapor permeability. Due to the good transmission of moisture and air, walls made of polystyrene concrete can "breathe", which ensures stable regulation of humidity.
4. Durability - as the operation progresses, polystyrene concrete blocks acquire additional strength. The declared service life exceeds 100 years.
5. The temperature range at which the use of the material is permitted varies from -60 to + 70 ° C.
6. Affordable cost - 1 sq. m walls made of polystyrene concrete will cost much less than another option.
7. Thermal inertia - buildings are effectively heated, while their cooling takes a long period of time.
8. Environmentally friendly - since cement, water, wood resin and safe polystyrene are used for the production of the material, the final product meets all environmental requirements.
9. Flammability class - in terms of fire safety, polystyrene concrete belongs to the NG1 class (non-combustible). The material is not afraid of the effects of open fire, since during ignition, the surface granules begin to evaporate.
10. Weight - blocks measuring 200x300x600 mm weigh no more than 18 kg. This characteristic provides a high masonry speed and reduced labor costs.
11. Strength indicators - a wall with a thickness of 30 cm is capable of withstanding a distributed load of up to 35 tons per linear meter. m.
12. Waterproofing properties - the material absorbs no more than 4% moisture, which is 4 times less than brick or wood. The likelihood of the formation of fungi is practically excluded.
13. Noise isolation - a 30 cm wall is capable of absorbing more than 70 dB of sound.

Application area

Before you start producing polystyrene concrete blocks with your own hands, you should consider the main areas of their application. Such structures are in demand when arranging screeds or internal partitions, erecting walls and insulating buildings for various purposes.

The material is also used in the production of facade panels or liquid solutions for pouring monolithic objects.