Producing concrete blocks on-site with Betonblock® moulds

Thinking about using natural materials like sand and gravel to make your interlocking concrete blocks? Our colleague René recently visited a quarry in France - or “carrière” as the locals call it - where this method runs in full swing. There’s no need to bring in sand or concrete mix. The only time transport is needed, is when the finished blocks leave the site.

How to use Betonblock® moulds for on-site block production?

Every site operates differently. Here’s how on-site block production works at the French quarry:

Aggregate extraction on-site

Vegetation, topsoil, and overburden have been removed to expose the raw sand and gravel deposits underneath. This way, sand and gravel come straight from the rock. Bulldozers and excavators lift the material directly, and conveyors move raw material from the pit to the processing plant. Sometimes hard rock is broken with crushers to create gravel.

Mixing the concrete

Cement, sand, gravel, and water are combined right on-site. There’s no need for ready-mix deliveries.

Filling the moulds

Empty moulds are placed on flat surfaces, after which release agents are applied to the inside. The concrete is then poured gradually into the mould, to ensure a proper filling of all the nooks and crannies. After the mould has been filled, the concrete is smoothened with a trowel.

Curing and storage

After 24 hours, the concrete blocks have hardened enough to be demoulded. Pins and wedges are removed, and the walls are opened. The blocks are then left to cure on-site for up to four weeks.

Sustainable block production using local resources

But why did this quarry start mixing concrete on site? Isn’t it easier to use a ready-made mix?

In France, they think differently. By using materials already available on site, you avoid transporting heavy, wet concrete altogether. Fewer transport movements and smarter use of local resources reduce CO₂ emissions and streamline the process. And with our moulds made from durable, powder-coated steel, you’re working with tools built to withstand tough conditions and regular use.

What to check before you start producing concrete blocks on-site

When they started producing concrete blocks on-site in France, they didn’t just jump in the deep end without proper preparations. Before you get started, check whether your site is ready for efficient concrete block production:

Is your location suitable for concrete block manufacturing?
Can you access local gravel or sand?
Are you able to manage curing conditions on-site?
Do you have enough space for blocks to cure for up to four weeks?
Is your setup designed for smooth mould placement and filling?

Why use Betonblock® moulds when producing concrete blocks on-site?

At Betonblock®, you get concrete block moulds that stand up to tough conditions. We use only high-grade S355 structural steel and finish every mould with a durable powder coating. These moulds last, even when you're working in rough terrain with loose rocks, gravel or mountainous ground.

Ready to simplify your production?

On-site concrete block production lets you create blocks right where your raw materials are, reducing transport and using resources efficiently. Want to find out how this could work for your project? Contact us for practical advice and examples from the French site.

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Producing concrete blocks on-site with Betonblock® moulds