Making Mini Concrete Blocks

One of the great things about this business is the fact that's not already a crowded market.  You have the opportunity to build it into just about any kind of specialty business you choose.

So, what are mini concrete blocks? 

Mini concrete blocks can fall into two main categories:

1. Educational Toys for Children

2. Model-Building Materials for Construction Projects

Educational Toys

As educational toys for children, the mini blocks are created to be used in building sets for children ages 8 and up.  The blocks are part of a set that should include the blocks, lintels, wood or plastic roofing material, and some washable or removable adhesive or mortar material (such as double-sided foam tape for indoor use).

Simple plans for several basic buildings should also be included, showing how the various pieces and materials are supposed to be used in construction.  Such plans should be detailed enough to help children understand the basics, without being so advanced as to require too much intervention by adults.

The aim of this kind of toy is to teach elementary building concepts that go beyond some of the more common wood building sets already on the market.  Children are like sponges when it comes to learning.  The essential concepts taught with this kind of toy will remain with them forever.

Construction Models

As working models for actual construction projects, the blocks need to be sold in large sets, and additional blocks must be made available for purchase, as needed.  Serious attention must be given to size and shape uniformity, and blocks must be to actual scale, so that measurements and comparisons can be made from the model sites.  The sets can be sold to large and small construction companies that want to provide the extra service and examples to their customers. 

Don't worry about competing with computer models and 3-D programs or other high tech "competition" in the market place.  There is always a market for real life models in construction.  Model sites created with these materials will often be kept for years, if not for generations.

Making the Blocks

Materials: Portland cement, sand or dirt, water, and possibly other filler materials, if you prefer.

Making the mini concrete blocks is not difficult, but thought should be given to your work space requirements, and to seasonal climates.  For example, you will need room for casting the blocks in molds, for any trimming or cleaning of the blocks after they are removed from the molds, and for final curing/drying and storage.  You will also need space for packaging.

Climate is important.  Unless your home and shop are located in a tropical or subtropical region, you will need a heated shop and work area.  Heating must be done safely, with consideration given to flammable molds, packaging, solvents, or other materials.  Rain, snow and humidity are other factors that will have a direct influence on your work, and on the storage of your raw materials and finished products.  Proper curing of concrete products is an important part of producing quality goods.  Make sure you take the proper steps to ensure the best possible results.

Building and using wood or plastic molds will enable you to cast your blocks in large quantities.  Make the molds in sizes convenient for frequent use, and don't forget that break-apart molds can make the work faster and easier.   Wood molds will swell when wet and shrink again as they dry.  This is not necessarily a problem so long as it is factored in.  Experimenting with simpler, smaller molds, at first, can help you learn how to make adjustments before spending more time and money on the molds you will actually use in everyday production.

Thought should be given to the fact that wood will swell and shrink with use.

As mentioned above, the blocks must then be given adequate room for drying and curing, as well as for storage.  Air ventilation is important, not only to the product but to the shop and surrounding materials.  Too much moisture over long periods of time will create problems you don't.  Make sure air can freely move through the shop, especially when concrete is setting up in the molds.  Wood molds should also be allowed to dry completely between uses.

 Thought must also be given to packaging, especially if the sets are to be sold in retail stores.  It may be best to consider using building centers and ranch supply outlets for retailing, since the materials will be in line with other construction products and merchandise.

While toy blocks do not need to be made to exact scale, they should still be close to the commonly used shapes.   This will give toy buildings more of a realistic appearance.

A common size for full scale commercial block in the United States is 8x8x16 inches, using the nominal measurements of 8 inch (20.3 cm) high by 8 inch (20.3 cm) deep by 16 inch (40.6 cm) wide. It's called a "nominal" measurement because the blocks are not made to exact size.  The actual size includes room for a bead of mortar, so the block itself measures 7.63 inches (19.4 cm) high by 7.63 inches (19.4 cm) deep by 15.63 inches (38.8 cm) wide.

Obviously, you will not need to worry about leaving room for mortar in a toy-scale version of the blocks.  A handy size for mini blocks might be 1/2 (1.27 cm) inch by 1/2 inch (1.27 cm)by 1 inch (2.54 cm).  The exact size is not critical, so long as all the pieces in the set are produced to the same scale.  Maintaining the scale is especially important if you decide to produce commercial model-building sets.

While it may seem that the better money is to be earned in producing blocks for construction models, this may not be the case.  There are far more children in the world than there are construction firms.  And educational toys have an intrinsically greater value to the world than tools for today's business needs, even though good tools are of great importance and value.

Alternatives to Using Cement

If the idea of making mini cement blocks doesn't appeal to you, there are some alternatives, if you still want to produce miniature construction materials, either for children or for commercial model applications. You can use clay, such as artists do. The results can be very good in many ways, but the cost is no comparison. Artist modeling clay is much more expensive, since it is a specialized material.

You can use wood. Once again, cost may become a big factor. Not only will you need a good supply of wood that may prove costly (depending on where you live and work, and what's readily available in your area), but you will need some woodworking tools, such as saws and sanders, if you plan to go into production.

Wood Building Blocks

Wood, however, may prove to be an excellent alternative, even if you go ahead with making the cement blocks. It never hurts to have more than one line of products, so as to broaden your market. Wood can be purchased at more a reasonable cost, if you can afford to buy and store it in large quantity. Be aware, however, that wood is very sensitive to moisture in the air. Storing boards waiting to be cut down into small blocks may not work out so well, if your shop is high in moisture. Adding moisture to wood will likely cause warping and curling, if given enough time. The opposite is also true. If your shop and storage area is unusually dry, your wood will split and warp. What this warping means is that precise cutting of the wood on a table saw can become a real problem.

There are ways to help control these problems. Avoiding long term storage is the easiest. Another is to try and help maintain an even and moderate humidity level in your storage area. It's usually best to avoid extremes in any attempts to control humidity. Stay simple, stay natural, and don't start any fires or run up a high energy bill. Keep in mind that woodworkers all over America (and around the world) in every kind of climate, have found ways to protect their inventory. In many cases, centuries ago.

Types of Wood

For small wood building blocks, you need a hard wood with a smooth grain. Pine is commonly available in most regions of the United States, but it has a strong grain. Depending on the type of pine, the grain may interfere with any coloring or finish. Pine is also very soft, and may prove too easily damaged by children's play or repeated use. Oak is a very popular wood for many projects and products, but again, the grain is open and easily splintered. Not good for children's fingers or face.

The best wood for building blocks will be something like a maple, which is very hard and very smooth. It will last through years of play or repeated use. Poplar is another alternative. Not nearly as hard as maple, but durable, and with a very smooth and closed grain. In the United States, poplar is not hard to find, and maple is also available.

Safety Concerns

There are other hardwoods available. Be careful of brittle, easily chipped woods that will leave sharp edges. Be careful to label any small products as unsafe for young children. Choking hazards must be avoided. Proper labels and marketing will help you avoid such dangers. If you decide to color or seal your wood blocks, make sure that your stains, paints are non-toxic. Avoid using products for color or finish that contain formaldehyde, which may be listed as Formol, Methanol, Formalin, dimethyloldimethylhydantoin, Methylene oxide or Methyl aldehyde.

One good source for non-toxic paints is Mythic Paints. Another is Milk Paint.. You can visit either site on the web.

Additional Safety Information for Products made for Children's Use

Consumer Product Safety Commission                Main Site: http://www.cpsc.gov

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