Many entrepreneurs who turn their attention to the building materials market are doing absolutely right. This area is developing rapidly and will continue to develop, since brick production will always be in demand in this area.
It is worth starting with the fact that the production of bricks is a very profitable activity, since the demand for it is always quite stable at any time of the year. The level of competition in the market is high, but with an increase in the pace of construction, there is a chance for potential entrepreneurs to occupy their niche.
We offer this niche, which is not occupied yet: production and sale of LEGO bricks and other concrete products (bricks, paving slabs, paving stones). LEGO brick is a high-quality building and facing product, formed by hyper pressing without firing. Hyper-pressing is based on the “cold welding” process, which occurs when finely ground limestone rocks with a small amount (up to 10%) of cement and water are pressed under high pressure. The main raw materials (up to 90%) are screenings from the development of limestone (carbonate) rocks: shell rock, limestone, dolomite, travertine, marble, limestone (dolomite) crushed stone screenings, as well as various screenings of soft rocks, etc. Using LEGO bricks, you can independently, thanks to two round structural guide holes, without the help of builders (whose work is very expensive), to assemble any outbuilding (fence, gazebo, shower, toilet, barn, etc.) and even a house on the principle of a children's LEGO designer. The result is a perfectly flat surface (again due to the two guide holes) - which does not require additional alignment. The brick can be placed on tile adhesive rather than cement mortar. There are 480 bricks in a cube. For the manufacture of one brick cube, 1350 - 1400 kg are required screenings (sands) and 100-150 kg. cement.
TECHNOLOGICAL PRODUCTION PROCESS
HYPERPRESSED LEGO BRICK
The main raw materials for the production of LEGO hyper-pressed bricks are screenings from the development of limestone (carbonate) rocks: shell rock, limestone, dolomite, travertine, marble, limestone (dolomite) crushed stone screenings, etc.
It is possible to use various kinds of sands (quarry, river) as raw materials, as well as screenings of harder rocks (granite, quartz, etc.). Good quality bricks are also made from these materials. But due to the high abrasiveness of these materials, the working surface of the equipment matrix will wear off faster.
The process involves semi-dry hyper pressing of the prepared mixture. The dropout moisture should be 7-10%. This can be determined using a moisture meter.
Four phases of the technological process
1) Preparation of the mixture
a) main raw materials (screenings) - 85 -90%
c) astringent additive (cement M-500) - 10-15%
The mixture is thoroughly mixed with a mixer-type mixer until a homogeneous mass and fed into the machine's hopper using a conveyor. It is not recommended to use a concrete mixer, as the mixture in it is not thoroughly mixed until smooth, does not break lumps and sticks to the walls.
2) Brick pressing
The prepared mixture through the dispenser enters the molding chamber, where the brick is molded under high pressure.
3) Brick palletizing
The molded bricks are stacked on pallets so that there is a free space of several centimeters between them. After 24 hours, the bricks can be stacked on top of each other.
4) Storage of finished products
Then the bricks, also on pallets, are delivered to the temporary storage warehouse before being sent to the buyer. The storage of bricks should take place at a natural temperature, not lower than 00, and always in the shade. Direct sunlight, when forming the strength of a brick, destroys its structure. The product can be shipped to the buyer 2 days after its manufacture. The brick gains its final strength after 28 days, like any concrete product.
Attention! The hopper of the machine during the release of bricks must be at least half full. This is necessary for the natural compaction of the mass entering the molding chamber.
The sand used, in order to achieve the maximum quality of the brick, must be homogeneous, with a fineness modulus of 1.8 - 2. The presence of clay must be no more than 3%. If large stones get into the mold chamber, it can damage the working part (matrix) of the mold chamber. Therefore, if there is a larger texture in the screenings, it must be sieved.
Due to the heterogeneity of screenings in the regions, the manufacturer must independently determine the screenings for brick production, based on the above, as well as the optimal composition of the compressed mixture.
To give the brick different color shades, it is necessary to use pigments (dyes) from different manufacturers. There are many options on the market at the discretion of the manufacturer. We recommend a powdery pigment from the German company Lanxess.
The quality of the produced hyper-pressed brick is also significantly influenced by various chemical additives, for example, construction plasticizers, which give it plasticity, increase the strength and density of bricks, etc. The manufacturer needs to select additives based on the screenings of the region where the bricks will be produced.
Plasticizers are an optional component of the prepared mixture. But their presence provides the initial strength of bricks (this is very important in limited production areas), improves quality (decreases cracking and abrasion of bricks), improves water resistance (water repellents) and frost resistance.
ABOUT THE PRODUCTION OF LEGO BRICKS