Semi-Automated Foamed Concrete Block Factory


Foamed (Cellular/CLC) Concrete Blocks Factory

The best way to make foamed concrete is in batches, as opposed to a continuous method. Foamed concrete blocks can be made by:

  1. Pouring foamed concrete into large moulds, to make large blocks, that are cut into smaller blocks when the foamed concrete is solid but has not yet gained any strength.
  2. Pouring the foamed concrete into a large mould that is sub-divided (partitioned) into smaller block sized moulds, when the mould is removed the blocks do not need to be cut.

To create a factory you need land, buildings, machines and equipment (silos for cement and sand, fast mixers for making slurry, slow mixers for blending foam into slurry, casting moulds, cutting equipment, storage racks, handling equipment, etc.), water, compressed air and electricity for powering equipment. Some of this is common to all factories, no matter what they produce. The rest is common to all factories which make concrete fabrications. The special equipment needed for making foamed concrete is the foam generator - several foam generators would be needed for efficient factory operation.

The photographs below show a semi-automatic factory with manual cutting of large foamed concrete blocks into small foamed concrete blocks. It is also possible to build a factory with a machine that cuts the CLC blocks automatically.

Raw Materials for making foamed concrete
Raw Materials for making foamed concrete
Sand and cement Silos
Sand and cement Silos
Pipes from silos to high shear mixer
Pipes from silos to high shear mixer
High shear mixer for making slurry
High shear mixer for making slurry
Mixer on elevated platform
Mixer on elevated platform
Horizontal mixer for blending foam into slurry
Horizontal mixer for blending foam into slurry
Adding foam to the slurry to make foamed concrete
Adding foam to the slurry to make foamed concrete
Mixing together foam and slurry
Mixing together foam and slurry
Fan on mixer for cooling mixture
Fan on mixer for cooling mixture
Foamed concrete is discharged into a hopper
Foamed concrete is discharged into a hopper
Large moulds for foamed concrete blocks
Large moulds for foamed concrete blocks
Filling moulds with foamed concrete
Filling moulds with foamed concrete
Cutting away surplus foamed concrete
Cutting away surplus foamed concrete
Cutting away surplus foamed concrete
Cutting away surplus foamed concrete
Checking surface of foamed concrete is level
Checking surface of foamed concrete is level
Demoulding foamed concrete block
Demoulding foamed concrete block
Wire Cutter for cutting foamed concrete blocks
Wire Cutter for cutting foamed concrete blocks. See also wire cutting machine
Foamed concrete block cutting guide
Foamed concrete block cutting guide
Cutting large foamed concrete block into small blocks
Cutting large foamed concrete block into small blocks
Cutting large foamed concrete block into small blocks
Cutting large foamed concrete block into small blocks
High humidity storage room for curing foamed concrete
High humidity storage room for curing foamed concrete blocks
Foamed (cellular) concrete blocks and pallets
Foamed (cellular) concrete blocks and pallets
Foamed (cellular) concrete blocks and pallets
Foamed (cellular) concrete blocks and pallets
Foamed concrete blocks used to build a wall
Foamed concrete blocks used to build a wall