Concrete Block

A concrete block refers to a block that is constructed using concrete material.

To enhance the quality of these blocks, it is essential to apply vibration and force during the
production process, ensuring that the mortar is thoroughly compressed. Concrete blocks
encompass various types, and here are a few examples for reference.

 Hollow blocks with different shapes and sizes.

 Solid blocks with different shapes and sizes.
 Curbstones in different shapes and dimensions.
 Paving blocks with different shapes, sizes, and colors.
 Grasscrete blocks (also called lawn stones).
  Concrete gutters also known as roof gutters.
 Lego concrete blocks
 Styrofoam concrete blocks
 hollow floor blocks also called Asmolen blocks

Concrete is a substance that is present in all the mentioned items, but you might be
wondering about its definition. Concrete is a composite material that comprises aggregates,
water, and Portland cement, typically in powdered form. These components are combined
in varying proportions according to specific standards for the mixture ratio. Moreover,
admixtures are available to incorporate additional functionalities into the concrete mixture,
allowing for customization and enhanced characteristics.

It's important to note the distinction between additives and admixtures in the context of
concrete. Additives are incorporated into cement during its manufacturing process to impart
new properties, while admixtures are introduced during concrete mixing to achieve specific
features.
The choice of aggregates used in concrete production can vary depending on the country.
Commonly used aggregates include limestone, shells, chalk, marl, shale, clay, slate, blast
furnace slag, silica sand, and iron ore. For further information on this topic, you can refer to
the Concrete Network. Additionally, our article titled "what hollow concrete block is in
general and in detail" provides in-depth insights into hollow concrete blocks.
Concrete Block Manufacturing Process

The process of manufacturing concrete blocks involves several steps, which can vary
depending on the system that is going to be used. These systems can be categorized as
manual, semi-automatic, automatic, or full-automatic, depending on factors such as your
location, labor costs, land prices, and budget. Here is a brief overview of these different
production processes for concrete blocks.

1. Manual Concrete Block Manufacturing Process:

The manual method is the simplest and cheapest way. It primarily requires molds, where
the concrete mixture is manually mixed and poured. However, the manual method lacks
vibration and high pressure, resulting in lower-quality concrete blocks.

Due to the manual mixing process, it becomes challenging to achieve consistent ratios each
time, affecting the overall quality of the final product. Additionally, the manual method is
time-consuming as it relies solely on manual labor. Consequently, this method is no longer
recommended as it lacks industrial advantages and efficiency.

2. Semi-automatic Concrete Block Manufacturing Process:

In the semi-automatic concrete block manufacturing process, a machine known as a
concrete block machine is employed. This machine features molds where the blocks are
produced under the application of pressure and vibration. The utilization of hydraulic
pressure and vibration in this process enhances the quality of the final product, surpassing
that of manual production.
However, it's worth noting that the mixing process is still conducted manually, leading to
potential variations in the concrete ratio with each batch. Furthermore, the pallets produced
by the machine require manual handling using hand carts, and the production process
necessitates the involvement of three workers. Therefore, compared to other production
methods, a higher number of workers is required.

If you have a limited budget and operate in a country with low labor costs and inexpensive
land, the semi-automatic concrete block manufacturing process presents itself as an optimal
choice for your business.
3. Automatic Concrete Block Manufacturing Process:
The automatic concrete block manufacturing method has gained significant popularity, as
reported by our sales department. One key advantage of this method is the automatic
preparation of mortar, ensuring consistent quality over time. The precise ratio of ingredients
is maintained consistently, resulting in reliable mortar quality.
In the production process, robots play an important role, reducing the need for manual
labor. Instead of using three handcarts, a forklift is employed to handle the production
efficiently. Moreover, cement is stored in a cement silo and automatically added to the
mixer, streamlining the process further. As a result, the number of workers required in your
plant can be reduced. It is important to note that the machine is operated by an operator in
this method, overseeing the overall operations.
4. Full-automatic Concrete Block Manufacturing Process:
In the automatic concrete block manufacturing method, an operator is required to operate
the machine. However, in the case of a full-automatic concrete block machine, the machine
operates automatically without the need for continuous human intervention. This design is
particularly well-suited for developed countries where labor costs are high and land is
expensive, as it allows for increased efficiency and cost-effectiveness in production.
Concrete Block Machine

There are different types of concrete block machines available in the market. Some of them
are mobile and some of them are stationary. There are also different automation levels for
the machines as well.

This article is about the concrete block production process so machine details are not
discussed here. If you are interested in learning more details about concrete block
machines you can read ''Brick Making Machine''.

Consider that to choose the right machine for your plant choosing the cheapest machine is
not wise at all. You need to consider technical info like pallet size, hydraulic pressure, power
consumption, and vibration force to choose the best machine. Bess offers you high-quality
concrete block machines with different capacities and automation levels. Below you can see
the concrete block production process done by our semi-automatic machine. You can
access more videos through our youtube channels BESS machine EN.
How To Produce Concrete Blocks

To produce concrete blocks you need to provide your plant with raw materials like
aggregate, water, and Portland cement. Then you need to mix them together to have a
homogenous creamy mixture. There are different mixture ratios available based on your
country's standards and aggregate availability. Also based on your machine choice it is
done manually or automatically.

After you prepare the mortar it is time to feed it to the machine. Usually, it is done by
conveyor belts. Then the machine takes care of the rest. the mortar is first poured into the
machine aggregate hopper then it automatically feeds the mortar to the molds. When the
mold is filled with mortar it is time for the hydraulic press to do the compressing. The
vibration also helps the hydraulic system to compress it in the best possible way.

After the concrete blocks are shaped over the surface of the pallets, the machine leads the
pallet toward the output of the machine. Now it depends on your machine if it is semi-
automatic it is delivered to the curing section by handcarts. these machines are also
called hollow block machines.

This process is the same in paver block machines too. the only difference is that the paving
block machines have a second hopper to apply different colors to the surface.
If your concrete block machine is an automatic machine then first, 5 pallets are stored on
top of each other and then they are taken by a forklift and delivered to the curing section.

If buying land costs too much in your area then it is better to choose the automatic system
to save land for the curing section up to 5 times.

Concrete Block Manufacturing Daily Capacity

Each day consists of three shifts and each shift is eight hours. It is easier to discuss the
capacity in each shift so there won't be any confusion.

Depending on the concrete block you are producing, the capacity of your concrete block
manufacturing plant is different. Usually, paving block production capacity is discussed in
square meters and the hollow blocks and solid blocks are described in numbers. The
concrete block machines offered by Bess can produce 4000 pieces of standard blocks
(20cm width x 40cm length x 20cm height) or 300 square meters of paving blocks in eight
hours.
Conclusion

To produce the concrete blocks based on your market demand and local availabilities you
need to choose the right machine and a suitable concrete block manufacturing business
plan. Bess engineers can help you in every step of this business. All you need to do is to
contact us.