Let us present the composition of the expanded clay concrete mixture with a specific gravity of 1500 kg / m 3 in the form of a table *.

Table 1: Composition of expanded clay concrete mixture

* Data are given for 1m3 of expanded clay concrete mixture.

With a decrease in the% content of cement and sand, the specific gravity of the expanded clay concrete mixture will decrease.

In the composition of light mixtures with a specific gravity of up to 1000 kg / m 3, sand may be absent, the content of cement decreases, and expanded clay - increases.

1.1. Cement (GOST 10178-85).

For the production of blocks, cement of a grade not lower than M-400 is required.

1.2. Expanded clay (GOST 9757-90).

Expanded clay is a lightweight porous material in the form of gravel, obtained as a result of firing low-melting clay rocks. Most often, for the production of expanded clay blocks, fractions of 5-10 mm are used.

1.3. Sand (GOST 8736-93).

Coarse or medium-sized sand is used as a filler, which creates the skeleton of the block.

1.4. Water (GOST 23732-79).

The use of water without contaminants is preferred.

2. Classification.

Expanded clay blocks are wall concrete stones and must comply with GOST 6133-99. They are classified by the following parameters:

2.1. By appointment.

• Thermal insulation (specific gravity 350-600 kg / m 3) - used for insulating buildings.
• Structural and thermal insulation (specific gravity 600-1400 kg / m 3) - used mainly for the construction of single-layer wall panels.
• Structural (specific weight 1400-1800 kg / m 3) - used for load-bearing structures houses and engineering structures (bridges, overpasses).

2.2. By application.

• Wall blocks- for the construction of walls (both external and internal).
• Partition blocks - for the construction of partitions.

2.3. Dimensions.

• GOST 6133-99 provides for the following block sizes for walls: 90x190x188mm, 190x190x188mm, 290x190x188mm, 390x190x188mm, 288x138x138mm, 288x288x138mm.
• The dimensions of the partition blocks are 190x90x188mm, 390x90x188mm, 590x90x188mm.

By agreement with the customer, the dimensions of the blocks can be changed.

2.4. By form.

• Solid - solid blocks without voids.
• Hollow - blocks with both blind and through voids formed during the manufacturing process to give the block the necessary performance characteristics.

3. Characteristics.

3.1. Strength.

Strength values ​​of expanded clay blocks:

• thermal insulation - 5-25 kg / cm2;
• structural and thermal insulation - 35 - 100 kg / cm2;
• constructive - 100 - 500 kg / cm2.

3.2. Volume weight.

Volume weight of expanded clay blocks:

• thermal insulation - 350-600 kg / m 3;
• structural and thermal insulation - 600 - 1400 kg / m 3;
• constructive - 1400 - 1800 kg / m 3.

3.3. Thermal conductivity.

Thermal conductivity of expanded clay blocks - 0.14-0.66 W / (m * K). Thermal conductivity increases with increasing cement content. According to this indicator, the thermal insulation blocks are at the level of the tree. Even constructive ones are preferable to concrete and brick. The use of hollow blocks in construction reduces the thermal conductivity of the walls and makes the house warmer.

3.4. Frost resistance.

Frost resistance increases with decreasing porosity. Minimum values(15 - 50 cycles) - for heat-insulating expanded clay blocks. For structural and heat-insulating - up to 150 cycles, for constructive ones - up to 500.

3.5. Shrinkage.

Shrinkage of expanded clay blocks is at the level of heavy concrete - 0.3-0.5 mm / m.

3.6. Water absorption.

Water absorption of expanded clay blocks - 5 - 10% by weight. The value can be reduced by adding complex additives and plasticizers to the expanded clay concrete mixture.

3.7. Water vapor permeability.

The vapor permeability of expanded clay blocks is 0.3-0.9 mg / (m * h * Pa). The value increases with increasing porosity and degree of voidness. For heat-insulating blocks, the values ​​are maximum, for structural ones, they are minimum.

3.8. Fire resistance.

The fire resistance of expanded clay blocks is 180 minutes at a temperature of 1050 C.

3.9. Price.

The cost of expanded clay blocks depends on the degree of hollowness, on the strength, which is determined by the content of cement, and is in the range of 2200-3500 rubles / m3.

3.10. Soundproofing.

Soundproofing properties of expanded clay blocks improve with increasing porosity. A partition made of heat-insulating blocks with dimensions of 590x90x188 mm provides sound insulation at the level of 45-50 dB.

3.11. Maximum number of storeys of the building.

Constructive expanded clay blocks allow high-rise construction. Possibility of erection of 12-storey houses

Table 2: Characteristics of expanded clay blocks

4. Advantages of expanded clay blocks in comparison with alternative materials.

• Environmental Safety... Expanded clay concrete is produced from natural materials(cement, sand, clay), which ensures its high environmental friendliness. The material was assigned the first class of radiation safety. It fully complies with modern sanitary and hygienic requirements in terms of sound insulation and vapor permeability.
• Thermal conductivity expanded clay concrete and the use of hollow blocks in construction makes houses made of this material warm.
• Low specific gravity expanded clay blocks allows you to save on foundation and transportation.
• Dimensions and weight of blocks reduce costs labor and grout when building walls, speed up construction.
• Low hydroscopicity and, as a result, high frost resistance increase the service life of structures made of expanded clay blocks, make it possible to save on wall protection.
• Application of blocks with through voids allows building inside walls power frames increasing bearing capacity designs.
• Low shrinkage values provide savings on cosmetic repairs.

5. Cons of construction from expanded clay blocks.

• Expanded clay concrete is inferior in strength heavy concrete... It is undesirable to use expanded clay blocks when constructing foundations.
• Imperfect block geometry.
• For multi-storey construction, it is necessary to use blocks with increased content cement. The consequence of this is the need for a more powerful foundation, deterioration of the thermal insulation qualities of the structure and a general rise in the cost of the project.

6. Scope.

Depending on the purpose, expanded clay blocks can be used for the insulation of houses, the construction of buildings (including multi-storey ones), the construction of engineering structures (bridges, overpasses).

7. Methods of transportation.

Transportation of expanded clay blocks is carried out by any transport on pallets. The height of the package with the pallet should not exceed 1.3 m. Stones with blind holes are placed with the voids down. Formed transport packages are stored in one tier. It is not allowed to carry out unloading and loading operations manually.

Comments:

Expanded clay concrete, the proportions of which must be observed exactly during preparation, is a high-quality construction material... It has managed to gain popularity in the market due to its properties comparable to traditional ceramic bricks. The houses turn out to be warm and comfortable, the blocks themselves can be easily made by hand, which only reduces the cost of work while maintaining the high quality of the products.

Proportions for the production of expanded clay concrete

The composition includes directly expanded clay, sieved quartz sand, Portland cement, an additive in the form of wood resin. Clean water is a must. The proportions used for mixing the mixture may vary. Their selection depends on the required density, concrete grade. The proportions of expanded clay concrete are selected for each case individually.

A mixture of ordinary expanded clay with a density of 1000 kg / m³ contains:

• Portland cement - 250 kg;
• clean water- 100-150 l;
• expanded clay - 720 kg (or 1.2 m³).

A solution with a density of 1500 kg / m³ has:

• PC M400 - 430 kg;
• expanded clay with a fraction of 5-10 mm - 720 kg (or 0.8 m³);
• sifted quartz sand - 420 kg;
• cool clean water - 140 liters.

Consumption is given per cubic meter of finished mixture, CP is used for grade M400. In terms of strength, the filler used has a class P150-200 with compression rates in B20... Other substances can be added to the composition, but in fact it is rarely used, more often in the factory. For self-preparation of blocks, a classic composition is used in the form of PC, expanded clay, water, sand.

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Binder for expanded clay concrete

How to make expanded clay concrete yourself? The composition resembles the usual one, only expanded clay, expanded clay sand are also added. The binder, which is the bulk, is high-quality Portland cement of the M400 brand, the amount of pozzolanizing additives in which is minimal. Plasticizers are not used for work in this case.

Portland slag cement and pozzolanic cement can be used, but this is determined empirically. If there is no confidence in the suitability of this mixture, then it is better not to experiment, but to use proven compositions and proportions. The problem is that just such substances, together with the dust contained in expanded clay, can cause a decrease in the water resistance and air resistance of building blocks.

When mixing, it is necessary to carefully observe the amount of cement, since an increase in its volume leads to an increase in the weight of the material, although the strength increases. If weight matters, then it is necessary to determine the "golden" mean when these indicators are perfectly combined with each other. That is why the use of Portland cement of the M400 brand is recommended.

It is better to use a hydrophobic binder after heat treatment, you can include alite cements with tricalcium silicate in an amount of 45%, tricalcium aluminate in an amount of 10-12%.

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Mixing water

The composition of expanded clay concrete necessarily contains water, like any other building mixture... The liquid should be taken only for drinking, which does not have any impurities. This will make the setting and hardening correct, the material will turn out to be of high quality, strong, durable.

In no case should you use wastewater contaminated with building admixtures to prepare the solution. Can not use sea ​​water, since salt efflorescence will remain on the surface after drying.

For the manufacture of expanded clay concrete with your own hands, you need to take clean cool water if the work is carried out in the hot summer time. The liquid should not be too cold, the minimum temperature is + 15 / + 18 0 С. В winter time concrete works experts do not advise doing it, but if there is no opportunity to wait, then the blocks are formed in a warm room, the water is slightly warmed up to prepare the solution.

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Aggregates for expanded clay concrete

To make expanded clay concrete, various aggregates are used. This is not only expanded clay sand, but also sifted quartz, large aggregates, for example, gravel. Expanded clay is the main ingredient in the mixture. This is a porous artificial material that is made from clayey fusible rocks by firing.

For light types of concrete, this particular material is the best option, since it has a porous structure, its surface is durable. The porosity level is close to about 70%, and the pores are up to 1 mm in size. Expanded clay provides excellent soundproofing, heat-shielding properties, concretes based on it are durable, lightweight, warm, perfect for the construction of low-rise country houses.

The form of the filler can be different, today expanded clay can be divided into the following varieties:

1. Gravel with an angular or rounded shape, the surface is melted.
2. Crushed stone, which has an irregular angular shape, the surface is rough, the pores are open, there is nostril.

Expanded clay by bulk density can be divided into 12 separate grades, but only 2 classes are used in terms of strength: A, B. Water absorption of gravel is 25% for 1 hour up to 400 brands, 20% - for grades 450-600, up to 15% - for grades 700-800. The material can withstand 15 freezing cycles, with a weight loss of up to 8%. Usually, for the preparation of a mixture for expanded clay concrete, expanded clay of 5-10 mm fractions and sand are used. Sand mix Is a material with a fraction of up to 5 mm, it is divided into 3 groups:

• large, the grain size for which is 1.2-5 mm;
• fine, grain size up to 1.2 mm;
• ordinary, the grain size is up to 5 mm.

When preparing the mixture, it must be remembered that sand prepared on the basis of expanded clay differs in adsorption of a high level in relation to the binder, water, therefore, the proportion of preparation should be observed exactly, do not change it.

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Production technology of expanded clay concrete

Making expanded clay concrete with your own hands is not so difficult. To make such blocks, you need to prepare:

• a concrete mixer, the volume of which is about 130 liters;
• a trough into which the ready-made mixture will be poured;
• expanded clay, the fraction of which is 5-10 mm;
• cement mixture;
• sifted construction river sand without clay inclusions;
• plasticizer (it is quite possible to replace it with ordinary soap in liquid form);
• clean, cool water, but not technical, but drinking.

The concrete recipe is as follows (based on 130 liters):

• clean drinking water- 5 l;
• Portland cement - 8 l (dry mix);
• liquid soap- 70 g;
• cleaned construction sand - 30 l;
• expanded clay - 30 liters.

First, you need to pour water into the concrete mixer, then add liquid soap (plasticizer) to it, add sand. The mass should be thoroughly mixed, gradually add expanded clay, dry cement. When stirring, the expanded clay mixture must be completely covered cement mortar, the mixture itself is homogeneous, perfectly mixed.

It takes about 7 minutes for one batch, you cannot mix the solution for too long, as its quality deteriorates. As a result, a mass resembling thick sour cream will turn out; there should not be any lumps or too strong fluidity.

Expanded clay is a lightweight building material with a porous structure. It is formed as a result of the influence high temperatures on low-melting clay.

Water

To prepare a mixture of expanded clay concrete, you must use water that meets technical requirements to the hardening of ordinary concrete. It should not contain harmful impurities that can spoil the process of setting and hardening of the binding components.

Can not use waste water with a pH of less than 4, as well as marine, which will cause white bloom on the surface.

Usually, drinking water is used to prepare the solution.

Placeholders

Expanded clay and quartz sand can be used as filler. Expanded clay as the main component gives the final product good heat and sound insulation properties. By form and outward appearance this material is divided into crushed stone ( irregular shape and rough surface) and gravel (round shape and melted surface).

Expanded clay gravel should lose no more than 7% weight in at least 15 freeze-thaw cycles. In the case of boiling, the loss of lime and magnesium oxide is maximum 5%. The higher the grade of expanded clay concrete, the less water it must absorb. So for M400 and less this value is 25%, from M450 to M600 - 20%, from M700 - up to 15%.

Fractions of expanded clay, the size of which is less than 5 mm, refer to sand (ordinary, fine or coarse).

Block mortar

To make a mixture, it is necessary to know exactly its composition and proportions, and also take into account what kind of material will be produced. If you need 1 part of cement, take 2-3 parts of sand and mix everything thoroughly. Then add 0.9-1 part of water and stir again. After that, up to 5-6 parts of expanded clay are added.

If the filler is too dry, you can add additional water to it. Components such as sand and cement can be replaced with Peskobeton. The resulting mixture is poured into molds, and the hardening process takes place in a special vibropress for 24 hours. After this stage, the blocks are dried in the open air.

And now let's talk about the composition of expanded clay concrete grade 200 (M200), 75 and other popular ones, as well as about compliance with GOST 25820-2000 and about other equally important nuances.

The following video will tell you about the proportions of the mixture for the production of blocks from expanded clay concrete, as well as about its preparation:

Special applications

Floor

The composition of expanded clay concrete for the floor - frequent question many people associated with construction. Expanded clay concrete includes several components that may differ depending on the purpose of use. So the flooring mix would include:

• Cement at least M500.
• Water;
• Sand;
• Expanded clay.

For floor screed the best choice will become expanded clay gravel. Moreover, by 0.5-0.6 cubic meters. m of expanded clay should account for 1.4-1.5 tons of a mixture of sand and cement. For a clearer example, the proportion looks like this:

• 1 tsp cement;
• 1 tsp water;
• 3 hours of sand;
• 2 hours expanded clay.

Let's talk about the composition of expanded clay concrete for walls further.

How such a screed is made from expanded clay concrete will be described in this video:

Walls

For the construction of walls from expanded clay concrete, you can use the following proportion to prepare the mixture:

• 1 h. Cement grade 400;
• 1.5 hours expanded clay sand (fractions up to 5 mm);
• 1 h. Fine expanded clay;

Walls built from of this material, are effectively used in low-rise construction.

Overlapping

For the construction of ceramsite concrete floors, you can use M400 cement. In this case, the composition of the mixture will be in the following proportions:

• 1 tsp cement;
• 3-4 hours of sand;
• 4-5 hours expanded clay;
• 1.5 hours of water;
• Plasticizer according to the instructions.

Depending on which proportion to adhere to, the final result, the strength of the material and its brand will depend. When using expanded clay of large fractions, a solution with low strength is obtained. It can be used as thermal insulation material. The use of small fractions makes it possible to create durable expanded clay concrete, which can.

The following video will tell you about the composition of expanded clay concrete for overlapping and the production of a mixture for it:

Expanded clay concrete is a building material based on expanded clay. Air granules are obtained by thermal processing of clay. Thanks to good performance heat insulation and light weight expanded clay concrete is used for floor screed.

Expanded clay concrete is a type of lightweight concrete intended for thermal insulation and construction of various structures.

This material has the following advantages:

• environmental friendliness;
• resistance to combustion and chemical attack;
• lack of corrosion;
• flowability, which allows you to level the differences on horizontal planes;
• soundproofing;
• strength;
• durability.

The composition of expanded clay concrete

This building material includes the following components: cement, sand, water, expanded clay.

Expanded clay concrete for screed can act as gravel, crushed stone or sand. The granules are oval in shape and medium in size. Crushed stone - multifaceted pieces large sizes with sharp corners... Expanded clay sand is obtained by splitting large pieces of material into small pieces.

For screed floors made of expanded clay concrete, gravel is used. The proportions for the screed in the classic version are as follows:

• cement - 1 part;
• water - 1 part;
• sand - 3 parts;
• expanded clay - 2 parts.

After pouring the floor from expanded clay concrete, the surface will need to be treated with a finishing screed. This is necessary in order to level the floor.

The proportions for screed floors made of expanded clay concrete depend on the method of pouring: dry or wet. The ratio of the various components makes it possible to obtain a solution of different brands.

To obtain expanded clay concrete M150, the proportions of cement, sand and expanded clay should be 1: 3.5: 5.7. The proportions of these elements for the M300 brand will be 1: 1.9: 3.7; for the M400 brand - 1: 1.2: 2.7.

For 1 square meter of screed 3 cm thick, 16 kg of cement and 50 kg of sand will be needed.

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Pouring of expanded clay concrete floor screed

They are distinguished by the method of pouring: wet, semi-dry and dry screed.

For wet screed the floor requires the following proportions of components:

• 1 part cement;
• 3 pieces of sand;
• 4 parts of expanded clay.

This means that for 25 kg of expanded clay it is necessary to take 30 kg of sand cement. Expanded clay gravel is poured into a large container and a small amount of water is added. The granules need to be under water for a while to absorb it.

Then cement and sand are added to this container, stirring constantly. It is necessary to stir until the granules become the color of cement, and the solution itself has acquired a viscous sour cream of a similar consistency. With a thick solution, add a little water.

Before pouring the screed, waterproofing must be laid on the concrete, otherwise the expanded clay concrete will not gain the required strength. From above, the flooded floor must also be covered with foil for 2-3 days so that the moisture does not evaporate.

Then it is necessary to carry out the finishing screed to align all the bumps. The result will be more effective if the floor is sanded before the final pouring.

The finishing layer should be no more than 3 cm. For its preparation, cement mortar is required, only without adding crushed stone. To achieve a flat surface, it is necessary to build new lighthouses from metal profiles, 27 mm high. Next, the finishing screed is poured, leveling with the rule.

It is possible to carry out two layers of the screed at the same time, which makes the structure more uniform. The method is as follows:

1. In a small area, expanded clay concrete is poured.
2. A guide profile is installed on the beacons.
3. A finishing screed is poured over it, leveling it along the profile beacons.
4. Start filling the next section.

Thus, the area is filled with separate sections.

The next day after the final pouring, the guide profiles are taken out, and the free grooves are filled with mortar. Laser level carry out a control measurement of the evenness of the floor.

Due to its light weight, the expanded clay concrete floor can be equipped even on attic floor from wooden beams... In addition, expanded clay concrete is cheaper than cement, which makes it more accessible to use.

Expanded clay concrete is the same cement mortar that is used to fill the screed. But since it is not heavy crushed stone that is used as a large aggregate, but expanded clay granules, the floor is warmer. Expanded clay is quite fragile and is not suitable for full leveling of actively exploited surfaces. Its main purpose is to create a light heat and sound insulating layer that does not significantly increase the load on the base.

To make expanded clay concrete with your own hands, you will need expanded granules with a size of 5-10 or 5-20 mm with bulk density 600-700 kg / m3. Fine sand is not so effective, but it is used for fine casting up to 30 mm. Coarse fractions are often used for dry and semi-dry screeds. The final choice depends on the loads on the future floor:

1. top scores show mixtures where all grain sizes from 5 to 40 mm are present in equal proportions. In this case, the screed turns out to be a little denser and heavier, but strong enough. At the same time, cement consumption is reduced.

2. To reduce the load on the floors, expanded clay is chosen larger. A finished screed with a large thickness can shrink over time, but this is the only way to even out serious surface drops, reaching 10-15 cm.

3. With a small thickness of concrete and the need to get rid of shrinkage phenomena, there is only one option - fine expanded clay sand.

As for cement, it is impossible to save here, since it alone depends on how tightly the expanded clay granules adhere to each other. At a minimum, it should be a binder with the M400 brand strength, but the more expensive PC M500 can also be used. The main thing is that Portland cement goes without substitute slag additives.

Increased requirements are also imposed on fine-grained aggregates, since they are also capable of influencing the strength characteristics of expanded clay concrete. This is the usual quarry sand, but certainly sifted and washed. To reduce the density of the screed and increase it thermal insulation properties it is better to choose larger fractions of sand.

Since the finished solution does not have sufficient mobility (its characteristics correspond to the lowest class P1), plasticizing additives are introduced into it to improve the workability of the mixture. You can use air-entraining modifiers such as SDO, which additionally porosize the cement matrix. But it is cheaper and easier to independently pour liquid soap into the concrete mixer at the rate of 50-100 ml per bucket of PC.

Proportions for different brands

To determine the scale of work, you will need to measure the area of ​​the room and calculate the height of the future layer of expanded clay concrete. The fill volume is the amount of clay aggregate in cubic meters, from which you should build on in further calculations. "Warm" monolith can be obtained in different densities - from 1000 to 1700 kg / m3 (although it is better to use the most durable coatings for the floor), in accordance with this, the proportions for the screed will also change.

With good moistening of expanded clay, 140-200 liters of water per cube of solution will be enough for such proportions. If soaking is not effective enough, the amount of liquid can be increased to 300 l / m3.

Traditionally, builders use a simplified ratio to obtain lightweight aggregate concrete of grade M100 - the "warm" screed that is optimal for building on their own. To do this, take 1 part of the cement:

• 3 hours of sand;
• 4 hours of expanded expanded clay;
• 1 h of water.

With such proportions, you can even purchase sand cement, where bulk materials just go in a ratio of 1: 3. If the screed is needed stronger, they simply choose a different cooking recipe for it:

When working with cement of a higher grade M500 and screed devices in household premises with operational loads not higher than average, it is recommended to use the following ratio of components per cube of expanded clay:

• 295 kg of cement;
• 1186 kg of coarse sand;
• 206 liters of water.

Lightweight screeds are prepared from expanded clay with a density of 200-300 kg / m3 without the addition of sand. Here you need to make a solution with the following ratio:

• 720-1080 kg of expanded clay granules;
• 250-375 kg of cement;
• 100-225 liters of water.

Expanded clay is poured into the container first. Before this, the granules must be soaked in water so that they are saturated with moisture and then do not pull it out of the concrete. After adding a little more liquid, sand cement is poured into the trough or drum of the mixer, thoroughly mixing the solution. With correctly selected proportions of expanded clay concrete, all granules in the manufacturing process should become the same gray- no brown spots.

If the mixture does not seem fluid enough, you can add a little more water to it. If there is an excess of moisture, dry components should not be poured, as this will not allow stirring them to homogeneity and will worsen the quality of expanded clay concrete, violating the cement ratio. In this case, it is better to let it brew a little, and then stir again.

Cooking should be done quickly and without delay. As soon as the granules are completely covered with cement slurry, the composition must be immediately poured onto the base, leveling along the established beacons. A mortar with expanded clay aggregate sets faster than ordinary concrete, but after a week it will be possible to move freely on such a floor. The final set of strength occurs within 28 days.

Features of working with expanded clay concrete

Before pouring, it is imperative to lay waterproofing on the floor or coat it and the lower part of the walls bituminous mastic... V otherwise moisture will be absorbed into the base, preventing the cement from gaining the required strength. Such a filling will turn out to be non-monolithic and very fragile - it will creep under load and dust. Also, around the perimeter of the room, it is imperative to secure a damper tape to compensate for thermal expansion. At the end of the work, the expanded clay concrete screed will require additional protection against moisture evaporation. To do this, cover it on top with a film, which can be removed in a couple of days.

The finished layer of "warm" concrete needs final alignment- preferably with preliminary grinding. From above, it is poured with ordinary sand-cement mortar with a thickness of no more than 30 mm (without adding gravel). This is enough to hide irregularities, but not worsen thermal insulation characteristics rough base. The finishing fill is performed along the beacons, carefully leveling the mixture with the rule. The slats are carefully removed the next day, and the remaining traces are sealed with fresh composition.

A semi-dry screed is another option for warming and leveling the floor using expanded clay, which allows you to process small areas in sequence. In this case, dry granules of expanded clay are poured onto the prepared base with installed beacons - to such a height that 20 mm of the beacon profile remain uncovered. From above they are spilled with liquid cement mortar (milk) and tamped, gluing the expanded clay grains together. After a day or two, the surface is poured with a finishing screed - the preparation of concrete for it is no different from the already discussed "wet" method.