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Foamed Cellular Light Weight Concrete

Foamed concrete, also called cellular light weight concrete is produced by the mixing a lightweight mortar result from water, Portland cement, fine sand including or alone fly ash and preformed stable foam. The foam is produced with the help of a foam generator by using foaming agent. The air content is typically between 40 to 80 percent of the total volume. The bubbles vary in size from around 0.1 to 1.5 mm in diameter. Foamed concrete differentiates from (a) gas or aerated concrete, where the bubbles are chemically formed through the reaction of aluminium powder with calcium hydro oxide and other alkalies released by cement hydration and (b) air entrained concrete, which has a much lower volume of entrained air is used in concrete for durability.

Batches Cellular Lightweight Concretemay be produce by mixing the above mentioned ingredients in ready mix plant or ordinary concrete mixer. Foamed concrete is self compacting concrete requires no compaction, and will flow readily from a pump outlet to fill mould, form, restricted and irregular cavities. It can be pumped successfully over significant height and distances. The 28 days strength and dry density of the material vary according to its composition, largely its air voids content, but usually they range from 1 to 25 N/mm2 and 200 to 1200 kg/m3. The plastic density of the material is about 150 to 200 kg/m3 higher than its dry density.

Continuous Cellular Lightweight Concrete production is made mixing light mortar (water with cement, fine sand and fly ash) and stable foam under pressure inside special static mixer.
You can deliver light mortar with a plastering machine similar PFT g4, with premixed materials (cement, fine sand and fly ash) from bags or silo.

pftg4

 

 

 

 


Rendering machine PFT G4
Foam is produced from special foam generator FG 120 connected with inlet static mixer SM250 near instead casting.
PICT00601

 

 

 

 


Foam generator FG120
Second inlet of static mixer SM250 is coupled with a pressure rubber tube from mortar producer at maximum 50 meters distance and 20 meters hight.

Static  mixer SM250
Static mixer use pressure energy to mix light mortar and foam and provide foam concrete to outlet.
He can command foam generator and has remote control for plastering machine.
Outlet static mixer will be at maximum 15 meter long.
Special foam generator FG120  produce a predetermined constant foam flow and has a pressure up to 4 bars.
turnat in perete

 

 

 


In situ casting

 

USES:

1. Foamed light weight concrete in the form of bricks, blocks or poured in-situ is used for thermal insulation over flat roofs or for cold storage walls or as non-load bearing walls in RCC/Steel framed buildings or for load bearing walls for low-rise buildings.
2. Fire rating of foamed concrete is far superior to that of brick work or dense concrete.
3. Bulk filling, using relatively low strength material, for redundant sewerage pipes, wells, disused cellars and basements, storage tanks, tunnels and subways etc.
4. Infill to the spandrel walls of arch bridges.
5. Backfill to retaining walls and bridge abutment.
6. Stabilizing soil, for example in the construction of embankment slopes.
7. Grouting for tunnel work.

Here we will look at the main feature of Cellular Lightweight Concrete and will compare it with other materials.
We  could produce foamed concrete with different densities from 200kg/cub.m. to 1200kg/cub.m.

Foamed concrete with this densities is used in roof and floor as insulation against heat and sound and is applied on rigid floors (i.e. in itself it is not a structural material). It is used interspace filling between brickwork leaves in underground walls, insulation in hollow blocks and any other filling situation where high insulating properties are required.

Used for the manufacture of precast blocks and panels for curtain and partition walls, slabs for false ceilings, thermal insulation and soundproofing screeds in multi-level residential and commercial buildings. Foamed concrete of this density range is also ideal for bulk fill application.

This material is used in concrete blocks and panels for outer leaves of buildings, architectural ornamentation as well as partition walls and floor screeds.
 Main features and characteristics of foamed concrete:

Type of cellular lightweight concrete

Sort of foamed concrete according to average density Kg/cubic meter

Non-autoclave foamed concrete

28 day compressive strength
Mpa

Thermal Conductivity
W/mk

Heat-insulated

400

1

0.1

500

1.4

0.12

Constructional-heat-insulated

600

3.5

0.14

700

5

0.18

800

7

0.21

1000

10

0.24

Constructional

1100

14

0.34

1200

17

0.38

The effects of foamed concrete density, cement type and content, water/cement ratio, foam type and curing regime will influence the compressive strength.

Water Absorption

Trials undertaken have shown that the closed cell bubble structure produced protein foaming agent create a foamed concrete with very low water absorption.
A fully submerged sample of a mid density (770kg/m3) foamed concrete absorbing just 13% of water by weight over a 10 day period. A dense concrete block submerged for the same time absorbed over 50% of water by weight.

Fire Resistance

Foamed concrete is extremely fire resistant and well suited to applications where fire is a risk. Test have shown that in addition to prolonged fire protection, the application of intense heat, such as a high energy flame held close to the surface, does not cause the concrete to spall or explode as is the case with normal dense weight concrete.

Common Information About Foam Concrete (Cellular Lightweight Concrete)

2-300x198

 

 

 

 

Foam Concrete is normal concrete with bubbles of air inside. Therefore it has the same characteristics with many additional advantages.
CLC (foamed concrete) blocks are used for building cottages, wall insulation in multistory buildings and internal partitions.
Also CLC can be produced and poured for floors and roofs on-site. In roofs it can be used because of very good insulating and lightweight. For floors CLC offers faster installation and a less expensive option because of the flowing and self-leveling properties.
CLC is easy to produce using our portable GS30 (GS40, GS50) foam generator. The ingredients are cement, sand, water and foaming agent. The components are mixed in usual concrete mixer and ad the stable foam produced in foam generator.
 The produced foamed concrete pour into the moulds for blocks, on the floor (roof) on the construction site or into screw pump and arise to fill wall.
Our company offer reliable equipment for producing cellular lightweight concrete.
We offer different equipments. We have sets for countries with major part of hand labor and sets for countries where better to use automatic equipment.
We ofer equipments for big productivity, up to 160 cub.m. of cellular lightweight concrete per 8 hours, with mostly automated operations.
For hot continental climate CLC (foamed concrete) is ideal material.
 ADVANTAGES OF CLC:
CLC being the typical concrete, it keeps gaining strength with time, so long as some moisture is available in the surroundings. It is therefore as weatherproof, termite resistant, fireproof and durable as any other concrete.
Cellular Lightweight Concrete is an environment friendly sustainable material produced with least energy demand.
Moreover CLC consumes a waste industrial product - Fly Ash - as one of its basic constituent materials thereby helping to reduce environmental pollution.
It substitutes use of burnt clay bricks, which are wasting precious agricultural soil and need energy for baking and kiln smoke vitiate the atmosphere.
Thinner walls in the case of CLC result in higher Carpet/Plinth area ratio (106% to 107%) in comparison to brick alternative.
CLC produced at project site saves energy expended in baking bricks, as also energy spent in transporting bricks/ dense concrete blocks to site of work. CLC blocks being lighter than bricks or Dense Concrete blocks save on labour deployed for on-site handling, masoning, cutting and filling chases etc.
The capital investment in production of CLC is far far less (in fact less than 0.03%) than the investment needed for producing Aerated Autoclaved Concrete. Only one low investment Foam Generator needs to be added to Concrete making establishment.
Being integrally cast as a lightweight reinforced shell, these cellular light weight concrete structures are highly resistant to earthquake shocks or storms in coastal areas.
Cellular light weight concrete, even in the structural grade densities, is nearly three times thermally more efficient than brick or mud walls. Therefore even thinner walls of CLC are better thermal comfort than single bricks/ dense concrete block walls.
Being industrialized system the speed of construction is very fast and the work can be executed mostly with the help of unskilled labour. 
Production of CLC is cheaper than normal concrete since fly ash, available free constitutes over 25% of its raw material contents.
Better strength to weight ratio .
Reduction of dead load resulting in saving of steel & cement and reduction in foundation size.
Better Acoustics and thermal insulation (Air conditioning requirement is considerably reduced).
Saving in consumption of mortar and Higher Fire Rating.
Resistance to fungus, vermin and rot .
When comparing foamed concrete with other materials, one must keep in mind that:
it is ecologically clean, breathes, uninflammable
easy to produce in steady-state conditions as well as on a construction site
is produced from components available in any region
selfcost of material is low
Below is a table in which thermal conductivity of foamed concrete is compared with that of other materials. Again, one must keep in mind that foamed concrete blocks can be laid on glue, which reduces frost bridges and, correspondingly, loss of heat.

Material

Density,
 kg/m3

Thermal Conductivity
W/mk

Marble

2700

2.9

Concrete

2400

1.3

Porous clay brick

2000

0.8

Foamed concrete

1200

0.38

Foamed concrete

1000

0.23

Foamed concrete

800

0.18

Foamed concrete

600

0.14

Foamed concrete

400

0.10

Cork

100

0.03

Silicate cotton

100

0.032

Foamed polystyrene

25

0.030

Foamed polystyrene

35

0.022