Ceramic block - progressive building material, which is one of the alternatives of bricks, the use of which is widespread in low-rise construction. This is an artificially created stone with a high percentage of emptiness, designed to masonry bearing and partition walls, overlaps and fences.
From this article, you will learn the production technology of ceramic blocks, their specifications, advantages and disadvantages, and also receive recommendations for the choice and features of blocking blocks.
Appointment, production technology
The strength characteristics of ceramic blocks allow us to use this material in the construction of residential and industrial structures with a height of 9 floors. It can also be used as a facing material when filling out frame buildings, in which case the stroke of the building is not limited.
According to the provisions of GOST №503, the material is called "stone ceramic", also common name as rated or warm ceramics, ceramic stone, large-format brick.
The technology of production of cerarmoblocks is similar to the production process for the manufacture of bricks. The material composition of the material includes the following components:
- lightweight clay;
- burning additives - sawdust, peat, straw, husk;
- water;
- chemical modifiers (if necessary, make the material improved performance characteristics).
Burning additives, they are replicators, provide a decrease in the density of clay under the firing by giving it a cellular structure. The greater the composition of the raw material added, the better there will be thermal insulation characteristics of the material, and the lower its strength.
A mixture of clay with a porizer is called the mixture, it passes the processing in the glinulating machine, where the material is frozen to the smallest fibers. Next, the blanks of the required form are generated from the mixture on the press extruder, the process is as follows - the mixture is moistened and enters the vacuum chamber, in which the air is removed from the charge, then the composition is pushed through the extruder fiber, which forms a ram with emptiness inside.
The bar is cut into blocks using a string cutting machine, after which the blanks are delivered to the dryer, where with gradually increasing from 35 to 110 degrees temperatures during 72 hours clarified. The next stage is a ceramic, which occurs in a tunnel oven at a temperature of 1000 degrees. In the process of ceramic, the porizers contained in the mixture burn out and the material acquires a cellular structure.
This manufacturing process is completed - the blocks are stacked on pallets and are packaged in the stretch film. Some manufacturers of ceramic blocks additionally grind the surface of the products, which allows you to perform their masonry on seamless technology using special glue. Also in clamoblocks, premium class of pores can be filled with basalt or polystyrene foam, which eliminates the possibility of entering the cell of the masonry solution.
1.1 Benefits and Disadvantages
The wide distribution of ceramic blocks in housing construction is determined by the presence of many operational benefits in this material. Consider the main advantages of cerarmoblocks:
- Porous kernels have a low thermal conductivity due to the presence of emptiness in its structure, it can be built from it a warm house with a minimum wall thickness.
- Large-format ceramic blocks are stacked much faster than brick, as the size of one block 380 × 250x219 mm replaces 15 standard bricks. This allows you to maintain a high pace of construction and save on the consumption of a masonry solution.
- Due to the cellular structure, the material is characterized by good sound insulation abilities.
- Corramoblocks are completely non-combustible, they do not allocate substances harmful to the human body when contacting with fire. The composition of the material contains extremely natural, environmentally friendly raw materials.
- Due to the low density (800 kg / m 3, which is comparable to the density of the tree) the weight of the cerarmoblocks is minimal. A small mass of the house of ceramic blocks makes it possible to build a building on a conventional tape foundation, saving on the laying of a powerful base.
However, it has porous ceramoblocks and disadvantages. Initially, we note the fragility of the material due to a plurality of internal voids - when it is transported, loading and unloading it is necessary to be as neat as possible. Also, the material is inclined to absorb moisture, to protect against which the waterproofing of the first row of masonry is required. The problem is both low frost resistance of ceramics, due to which there is a mandatory need to facade the facade of the house with brick, thermopanels or its coating with thermally resistant plaster.
Specifications of material:
- density - 780 kg / m3;
- class of frost resistance - F25;
- volumetric water absorption - 12%;
- parry permeability - 0.14 g / μpa;
- sound absorption - 53.5 dB;
- thermal conductivity - 0.25 W / MK;
- strength class - M100;
- emptiness - 50%.
The dimensions of the ceramblocks are defined in the Regulatory standard of GOST No. 530 "Brick and Ceramic Stone", according to which there are 14 product sizes. The most common of them are:
- 250 * 120 * 140 (replaces 2.1 bricks);
- 380 * 250 * 219 (replaces 10.7 bricks);
- 510 * 250 * 219 (replaces 14.3 bricks).
The following differences between the actual sizes are allowed from standard: width - 5 mm, thickness - 5 mm, length - 10 mm. In each sizes of blocks, the thickness of the outer wall should be 8 mm. The difference in ceramic products from other masonry materials is the presence of oxide compounds on side edges, preventing the occurrence of cold bridges on vertical seams.
1.2 Curleumoblocks Porotherm (video)
The leader in the global production of ceramic blocks is the company "Porotherm" (Germany). This is one of the first manufacturers of paranible cerarmoblocks, which has been operating since 1869. Today, the company owns 230 plants around the world, 2 of which are located in Russia.
The assortment of porothers presents the following types of ceramoblocks:
- Porotherm 51 - large-format wall blocks for masonry of bearing walls;
- Porotherm 51 ½ - Dobly blocks for the dressing of vertical seams;
- Porotherm 20 - blocks for filling openings in frame buildings;
- Porotherm 12 and 8 - wall blocks for masonry interior partitions.
Among domestic manufacturers, Ceramic blocks of ketter deserve attention, the cost of which is 15-20% lower than that of the porother. The company produces and supplies the Ceramoblocks of the NF 2.1, 10.7 and 14.3 to the market. A characteristic feature of this company's products is that blocks are available in different shades - from brown to dairy, which expands the design capabilities of the architect.
Also on the market is presented a fairly large number of organizations offering services for the construction of houses and cottages turnkey. Such companies provide customers with directories in which you can choose the finished projects of cottages of different areas - from 40 to 200 m 2. At the same time, the contractor assumes all the construction stages - from the zero cycle to the decorative decoration of the building.
2.1 What solution is needed for masonry of ceramoblocks?
Laying blocks can be performed using a conventional cement-sand solution, but block manufacturers recommend using a special adhesive composition. When using glue that does not form a cold bridges, it is possible to increase the heat-saving characteristics of the wall by 15-20%.
Adhesive for cerarmoblocks is often called "warm solution". Its characteristic feature is the presence of a porous filler, as a rule, a perlite is used. The "warm solution" is more expensive than conventional masonry adhesives, however, due to the fact that under the masonry of the cerarmoblocks, there is no need to fill vertical seams with a solution (due to the presence of the groove-comb system), the increase in costs will be minimal.
The proven formulations of the "warm solution", the quality of which is not in doubt - KTS Cleaning and Rodozit 231. It is often possible to meet the recommendations that the walls from the ceramoblocks need to be reinforced by a masonry grid, but in practice it is used exclusively in order to in the cavity in the cavity The blocks did not fail the solution, and not to strengthen the masonry, the stock of the strength of which for low-rise buildings is enough. When working with blocks of leading manufacturers, there is no need to use a masonry grid at all, since the geometry of cavities in them is chosen so that the glue does not fall into the pores.
In recent years, many new types of wall materials have appeared, which have high thermal insulation. However, the desired effect turns out to be incomplete when using a traditional cement-based masonry solution. The seams are not distinguished by good thermal insulation, it is through them that the buildings are cooling and an increase in the costs of their heating occurs. Also, conventional solutions can cause formation on the surfaces of mold walls.
Thermal insulation masonry solution will solve the problem. Special compositions help maintain the heat engineering parameters of the wall and reduce the heat loss of seams between bricks or large-format blocks. When they are manufactured, porous materials are used, one of which may be perlite.
Features of thermal insulation masonry mixtures
Thanks to the thermal insulation mixture, you can get homogeneous masonry. They have a special composition that allows you to get plastic and durable material with high strength. The heat insulating masonry mixture prevents the formation of cold bridges. Thanks to it, good vapor permeability is ensured. Some manufacturers of ceramic blocks and other heat-insulating materials are recommended for their masonry, warm mixtures were used.
When choosing a thermal insulation mixture, it is necessary to consider such parameters:
- density;
- frost resistance;
- compressive strength;
- coefficient of thermal conductivity;
- use temperature.
Due to the frozen of the porous material, the density is reduced and the thermal protection of the material increases. Empties in it that prevent heat loss are created through the use of special substances - ceramisite, perlite, pumice or vermiculite. When preparing a mixture at the construction site, to obtain a uniform distribution of the heat insulating filler. This means that high-quality composition can be made exclusively in factory conditions with careful compliance with technology.
The warm solution must have the following characteristics:
- plastic;
- high heat insulation;
- sound absorption;
- good adhesion;
- decorative attractiveness;
- low density;
- high-quality filling of the seam.
Preparation of thermal insulation mixture
The composition should be covered in a warm water tank (about 10 liters of water requires 25 kilograms of the mixture). After that, it is mixed until the formation of a homogeneous mixture. The solution should stand up to 5 minutes, then it is rejected again for several minutes. It must have a sour cream-shaped consistency. In the masonry mixture it is impossible to enter third-party substances or additives.
The company "Slavda" offers to purchase heat-insulating masonry mixtures of manufacturers such as RAUF THERME, POROTHERM, PEREL. They are delivered to all cities of the Russian Federation. You can get closer with the products in one of our offices, which are located in Moscow and St. Petersburg. Contact! Our employees will help you choose the optimal masonry solution for your purposes!
Warm masonry solution is a construction mixture for cellular concrete products: foam concrete, aerated concrete, gas silicate, phenosilicate and porous ceramic blocks.
Replacing the usual cement mixture on the "warm" increases the thermal insulation of the masonry by 17%.
The binder in this mixture traditionally serves as cement, and fillers are pumice, perlite, clay sand.
The warm solution is also called "easy", due to its weight and low density.
Replacing the usual cement mixture on the "warm" increases the thermal insulation of the masonry by 17%. This effect occurs due to different thermal conductivity coefficients. In the cement-sand mixture, this indicator is 0.9 W / m ° C, and the "heat" is 0.3 W / m ° C.
Characteristics and basic properties
From the school year of physics, the fact is known for a long time that the air does not spend heat. Based on this, it suggests a logical conclusion: so that the construction structure from porous materials retains the heat well, the air absorbing substances should be included in the solution. Most often with such fillers serve perlite or clay sand.
Exterior wall structures are often performed from lightweight materials with a high thermal resistance coefficient. In this case, a mixture of smaller density is needed as a binder, rather than traditional cement-sand. The latter has a high density (up to 1800 kg / m3), resulting in additional heat loss due to the "cold bridges". If the density of the binder "test" exceeds the density of the wall material at every 100 kg / m 3, then the weight loss of such a design increases by 1%.
If the density of the binder "test" exceeds the density of the wall material at every 100 kg / m3, then the weight loss of such a design increases by 1%.
So that this physical characteristics of the binder mixture and the wall material is comparable, it is necessary to prepare a special "warm" solution, the density of which would be 500-800 kg / m 3. This composition should have a high plasticity, crack resistance, good adhesion, moisture-hold abilities, sufficient viability.
The strength of the construction structure is more dependent on the wall material, and not from the brand of composition. The latter brand, as a rule, should coincide with the technical characteristics of the brick. However, when using a mixture on one brand below, a decrease in the strength of the masonry drops by only 10-15%.
The minimum stamps of solutions (from M10 to M50) are used for buildings 1 degree of durability, as well as for masonry of low-rise buildings from highly phased materials, the strength of which is 3.5-5 MPa. Thus, for this type of construction, binding mixtures with strength from 1 to 5 MPa should be used.
Additional decrease in density
The average density of the binder composition, as mentioned above, reduces the use of low-plate fillers. However, the reduction in the density of the mixture can be achieved in the presence of a traditional filler - sand. When using turbulent mixers and air ducting additives, the density can be reduced from 1600 to 900 kg / m 3, which corresponds to the strength of 0.3-4.9 MPa. This mixture corresponds to M4, M10, M25 brands.
One of the ways to reduce the density of building mixtures is to prepare a solution with the help of special mixing equipment - steam generator. A good effect can be achieved when pouring cement stone on turbulent mixers. This technology is applicable only with the use of airflowing additives.
The most effective method of preparation of a warm solution is the simultaneous use of porous aggregates and air-flowing additives.
The choice of the type of porous aggregate depends on the composition of the raw material base, operating conditions, the average density of the wall material. Traditional aggregates should be a density of 800 to 500 kg / m 3 and have strength up to 10 MPa.
Preparation of mixes
Warm masonry solution is often used to erect the outer walls, the traditional cement-sand mixture is used for the inner walls. This composition can be prepared with your own hands or with a mixture mixer at low speed. To prepare this "construction test", you can use ready-made mixes in which you need to simply add water and mix. If the binder is planned to be prepared with your own hands, then all components are stirred in a dry state, and then water is added.
The "warm" mixture is prepared in such proportions: 1 part of cement and 5 parts of the filler (clay or perlite sand). The dry mixture is stirred, and then 1 part of the water is added to 4 parts of the dry mixture. The mixed solution should stand 5 minutes, then it can be used for its intended purpose.
The cooked "dough" should be a medium consistency. Overly, the liquid composition will fall in the voids of the blocks, thereby preventing thermal insulation.
Construction work is best done in the warm season. The cause of such seasonal preferences are not only favorable weather conditions for work on the street, but also the fact that at low temperatures a masonry solution is frozen. However, if it still has to operate at air temperature below 5 ° C, special additives add to the solution. But even such "antiorious" impurities do not save the laying from reducing strength.
The heat-saving mixture provides masonry of the walls more homogeneous, despite the fact that the amount of solution in it is only 4% of the total area! Warm masonry solution allows you to maintain heat as much as possible, reduces the weight of wall structures, and also reduces the consumption of building materials.
Didn't find an answer in the article? More information
Many customers and builders are conceived - is it worth buying a special warm mixture for masonry ceramic blocks or limited to the usual CRCC solution? Undoubtedly cement-sandy mixture is cheaper, but at the same time it does not have some important technical characteristics.
Advantages of warm solution
- Specially designed for invoked cerarmoblocks to reduce heat loss through dissolved seams
- Thanks to the special composition with perlit, the mixture is very convenient to use, it is plastic and does not fall into emptiness
- Thermal insulation properties are 4 times better than the conventional solution
- The output of the finished mixture of 1 kg is 1.6 times greater than that of a conventional solution
- Simple preparation of the mix - just added water
Warm solutions
What kind of problem is the warm masonry solution solve? According to statistical data, about 15% of heat in the house flows through dissolved seams. By choosing a warm mixture for masonry of ceramic blocks, you will improve the heat engineering properties by 15%, respectively. Since the thermal conductivity of the solution is almost identical to the thermal conductivity of the ceramoblock, the wall can be called monolithic.
In addition to the original Porotherm TM solution, analogues have long been present on the market for a long time, according to quality, not inferior to the original, such as Perel masonry mixtures.
Heat-insulating heat saving masonry solution
But, the use of glue to fill the seams when laying single-layer walls from as well as ceramic, ceramzite concrete, arbolite blocks, and blocks from other materials, possibly only when used blocks with deviation of size in height not more than +/- 1 mM.. (Category 1 to deviate geometric parameters).
Not all manufacturers produce such blocks. Yes I. at a price, blocks with a deviation of the size in height are not more than +/- 3 mM.. (Category 2). These blocks need to be put into the wall on the solution with a thickness of the seam 8-12 mM..
The use of a conventional cement-sand solution for masonry of external single-layer walls from blocks significantly reduces their heat shielding properties. The thermal conductivity coefficient of masonry increases to 30% compared with masonry on glue (for D400-500 blocks). It's too much.
Therefore, for masonry of external single-layer walls from blocks, heat-insulating light warm solutions with a density in dry state less than 1500 should be applied kg / m 3.
How to prepare heat-insulating masonry solution
Warm lightweight masonry solution is prepared using cement and light aggregates - clay or pelite sand, polystyrene granules.
Perlite is the rock formation of volcanic origin, frozen stone foam.
D. the oarrage into the composition of the mixture of lime increases the plasticity of the solution.
Warm lightweight masonry solution convenient to cook fromdry masonry mixture.In the construction market you can find ready-made dry mixtures of various compositions for the preparation of heat-insulating masonry solution.
For example, a dry masonry mixture of one of the manufacturers based on cement, mineral aggregate - perlite and plasticizing additives has the following characteristics:
The name of the mixture is a mixture of dry thermal insulation.
Compression Strength - M50.
Coefficient of thermal conductivity ( W / M ° C) — 0,21 / 0,93
Average density ( kg / m 3) — 1000 / 1800
Solution output from 20 kg. Dry mix - 34 l.
Frost resistance - 25 cycles
Shelf life - 12 months.
(Through Slash (/), the value is indicated for a conventional cement-sand solution).
From the given data, it can be seen that through the seam from the conventional solution is lost in 4 times more heat than through the seam from the heat-insulating solution.
The method of preparing the solution is usually indicated on the packaging of the finished dry mixture. The exact execution of the recommendations specified on the package ensures that the solution with good plasticity and clutch with the masonry blocks is guaranteed.
When choosing a finished dry mixture, not only the price should be guided, but also recall what volume of the finished solution is obtained from one packaging. For example, from a 25-kilogram bag of a dry mix of one of the manufacturers, 40 liters of the finished solution are obtained, and the same by weight packaging of another manufacturer will allow you to prepare only 18 liters of solution.
The amount of the finished solution that can be prepared from a dry mixture should be indicated on the packaging of the goods.
When buying a dry mixture, also pay attention to the thermal conductivity coefficient - the less, the better.
Composition of cement light solution for blocking blocks
For independent preparation of a warm lightweight milestone M50 brand in the table there are several recipes:
|
Mark on the density of the solution kg / m 3 |
The ratio of components by mass |
Materials |
|
Cement: Lime: Ceramzite sand |
||
|
Cement: Sand from Aerated Waste: Lime: Perlite Sand |
||
|
Cement: Sand Quartz: Perlite Sand |
note - Dosage of binder, aggregates and additives should be made by mass.
To improve the plasticity of the solution, hydrophobic or air-proof additives are used in an amount of up to 0.2% of the mass of cement.
With a decrease in the density of the solution, the coefficient of thermal conductivity is reduced.
When preparing a solution into a container, 50-70% of water, aggregate and cement, which are mixed for 1-2 minutes are loaded. After that, the composition is mixed with the rest of water and additives.
Perlite grains are very fragile. With prolonged stirring in the concrete mixer, they are crushed, which reduces the heat-saving properties of the solution. Do not interfere with a solution with a perlit longer than necessary.
When laying the unit is lowered on the solution from above, avoiding horizontal movement over 5 mM.. The extruded surplus of the solution is removed immediately, not allowing their setting. Richtovka blocks can be swinging or a picking tool that excludes mechanical damage.
The surface of the block before applying the solution is recommended to be wedged with water.
In the process of masonry, it is necessary to provide protection for the seams of masonry from too fast drying and atmospheric influences - the sun, rain, frost.
Consumption of the block laying
For masonry 1. m 2. Single-layer wall from smooth blocks thickness 30 - 40 cm. Approximately it is necessary 20 - 30 liters of solution With the thickness of the seam 10-12 mM..
For buildings height 1-2 floors you can even more reduce heat loss through the souls of the solution, as well as to reduce its consumption. For this, the solution in the masonry is applied by two strips along the outer and inner surface of the wall, leaving the air interval in the middle of the wall in the seam 1/3 - 1/4 of the block width. This measure reduces the thermal conductivity of the seam, but at the same time reduces the supporting ability of masonry - therefore it is used only for buildings of a small height.
A smaller amount of solution will be needed if it is for masonry to use blocks with a groove-crease compound of vertical joints. Vertical seams in this case are not filled with mortar.
The use of a warm lightweight mosquito solution allows to significantly improve the thermal conductivity of the wall compared to a conventional solution, but not so much to become equal to the adhesive seam. In addition, glue consumption is several times less than a light solution, and the price of ready-made dry mixes of glue and the solution is almost the same.
Next article:
Previous article: