The process of making concrete blocks involves several key stages, from mixing raw materials to curing the final product. Here's a step-by-step breakdown:
1. Mixing
- Material Transfer: Sand and gravel (aggregates) are transported to storage bins using a conveyor belt system. This ensures a continuous supply of materials for block production.
- Proportioning: The aggregates, cement, and water are carefully measured and proportioned according to a specific mix design. This is crucial for achieving the desired strength and durability of the blocks.
- Mixing Process: The measured materials are then fed into a concrete mixer. The mixer thoroughly combines the aggregates, cement, and water to create a homogeneous concrete mix.
2. Moulding
- Conveying the Mix: The concrete mix is discharged from the mixer and transferred to an inclined concrete block conveyor.
- Hopper Filling: The conveyor transports the mix to an elevated hopper, which feeds the block molding machine.
- Molding: The concrete mix is then fed into molds within the block molding machine. This machine compacts and shapes the concrete into the desired block dimensions. Vibration is often used to ensure proper compaction and eliminate air pockets.
3. Curing
- Initial Setting: The freshly molded blocks are carefully removed from the molding machine and placed on racks. These racks are then moved to a curing area.
- Moist Curing: The blocks are cured under controlled temperature and humidity conditions. This typically involves maintaining a high humidity level to prevent the concrete from drying out too quickly. Sprinkling with water or using steam are common methods. Curing is essential for the hydration of cement and the development of strength in the concrete.
4. Cubing
- Inspection: After curing, the blocks are inspected for quality and any defects.
- Stacking: Blocks are stacked, often by automated machinery, into cubes for easy handling and transportation.
- Distribution: The cubed blocks are then ready for distribution to construction sites and other customers.
