Equipment for foamed concrete and cellular lightweight concrete production > Description of foamed concrete material

Foamed concrete (synonym cellular lightweight concrete) – definition and physical characteristics.

Foamed concrete is a type of porous concrete. According to its features and uses it is similar to aerated concrete. The synonyms are:

  1. aerated concrete
  2. lightweight concrete
  3. porous concrete

Foamed concrete is created by uniform distribution of air bubbles throughout the mass of concrete. Foamed concrete is produced by mechanical mixing of foam prepared in advance with concrete mixture, and not with the help of chemical reactions. Foam is prepared in special device – foam generator and after that mixing in special mixer. (For example machine Fomm-Prof consist from special mixer and foam generator mounting together).

Here we will look at the main feature of foamed concrete and will compare it with other materials.

Fomm-Prof machines could produce foamed concrete with different densities from 200kg/cub.m. to 1600kg/cub.m.

  • Density 300-500 kg/m3 (19-38 lbs/ft3) Made with Cement & Foam Only

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.

  • Density 600-900 kg/m3 (38-56 lbs/ft3) Made with Sand, Cement & Foam

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.

  •  Density 1000-1200 kg/m3 (56-75 lbs/ft3) Made with Sand, Cement & Foam

This material is used in concrete blocks and panels for outer leaves of buildings, architectural ornamentation as well as partition walls, concrete slabs for roofing and floor screeds.

  • Density 1200-1600 kg/m3 (75-100 lbs/ft3) Made with Sand, Cement & Foam

This material is used in precast panels of any dimension for commercial and industrial use, garden ornaments and other uses where structural concrete of light weight is an advantage.

 Main features and characteristics of foamed concrete:

Type of foamed concrete Sort of foamed concrete according to average density

Non-autoclave foamed concrete

28 day compressive strength

MPa**

Thermal Conductivity

W/mk

Heat-insulated

D400

1

0.1

D500

1.4

0.12

Constructional-heat-insulated

D600

3.5

0.14

D700

5

0.18

D800

7

0.21

D1000

10

0.24

Constructional

D1100

14

0.34

D1200

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 GreenFroth protein foaming agent create a foamed concrete with very low water absorption.

The higher the air content the higher the water absorption figure with 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)

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 Fomm-Prof process machine. The ingredients are cement, sand, water and foaming agent GreenFroth. The components are mixed in Fomm-Prof machine and in this mix added the foam that produced in special foam generator that attached to Fomm-Prof machine. The produced foamed concrete pour into the special moulds for blocks or on the floor (roof) on the construction site. It poured by hose, that attached to Fomm-Prof machine. You don’t need any additional devices to transfer foamed concrete from Fomm-Prof machine to moulds to floor (roof).

Our company offer equipment, ingredients and full technology for producing foamed concrete. We can provide our clients with full set of equipment and they immediately after delivering can start production of foamed concrete blocks or pour it on construction site.

We offer different sets of equipment. We have sets for countries with major part of hand labor and sets for countries where better to use automatic equipment.

Especial set for Africa, Asia, South America (small and average productivity, up to 100 cub.m. of blocks per day, with mostly operations by hand manual).

Especial set for Europe, Northern America, Australia (big productivity, up to 150 cub.m. of blocks per day, with mostly automated operations).

For hot continental climate CLC (foamed concrete) is ideal material.

In Kazachstan, Iran, Kyrgyzstan, Uzbekistan our clients already successfully use foamed concrete. In countries with hot continental climate usually very hot during the day and cold in the night. So at afternoon outside surface of wall can have a temperature about +90 C, and in the night about + 10. Because of this you have to built thick walls or use conditioner all day long. The foamed concrete can keep ideal temperature inside the house all day with only 40 centimeters wall’s thick.

For countries with tropical climate CLC (foamed concrete) is ideal material.

In India, Vietnam, Malaysia, South Africa Foam our clients already successfully use foamed concrete. Foamed concrete is extremely water resistance material. It can float over 30 days in water, before go down. Also this material can’t be eaten by insects and mice.

For countries with cold climate CLC (foamed concrete) is ideal material.

In Canada, Russia, Ukraine our clients already successfully use foamed concrete . In countries with cold climate most of energy is spent to heating. So, usually, houses are built with thick walls or with 2 layers – brick and thermal insulation. With foamed concrete it is possible to use only 1 material for all house – for walls, internal walls, floor and roof. As a result you will have very durable and solid house. This house will be warm because foamed concrete is very effective isolating material. For example in northern Russia it is enough to make walls only 40 centimeters thick.
 

Advantages

RELIABILITY
It is very long-lived material. After producing it in first 90 years it increases solidity. It does not decompose and is as durable as rock.

RESISTANCE TO COLD AND WARMTH
It is very effective isolating material. Buildings constructed from foamed concrete are able to accumulate cold or heat, which allows to greatly minimizing conditioning or heating expenses. It is ideal material for countries with hot and cold climate and it is successfully used in Australia, India, Malaysia, Canada, Sweden, Russia and other countries.

MICROCLIMATE
Control air humidity in a room by absorbing and output of moisture during the day and night. Also in foamed concrete houses is favorable average temperature during the day. For example if in the night temperature is about 0 Celsius and in the day about +50 the average temperature in the house will be about + 19 Celsius.

FASTER CONSTRUCTION
Blocks are lightweight, big sizes and high accuracy dimensions. It increases the construction speed for several times. Also it is easy to cut channels and holes for electrical wiring, sockets, and pipes.

ACOUSTIC INSULATION
It has a high property of acoustical absorption. If foamed concrete pouring to floor or roof if fill all holes and caves in construction and this is also increase acoustic insulation.

ECO-COMPATIBILITY
It does not produce any toxic substances and in its ecological compatibility is second only to wood.

HIGH WORKABLE
It is a high workability material, so it is possible to build various shapes of corners, arches, pyramids, which will attach beauty and architectural expressiveness to your house.

BIG PROFIT
Allow to save big money not only during living in the house, but during the construction the house too. It is cheaper to deliver, to build, to make foundation for this house, to plaster, to drive a wires and sewerage tubes, to build various shapes of corners and arches.

SUPERIOR FIRE RESISTANT
Extremely fire safe. For example foamed concrete used in special fire safe vault. Tests show that foamed concrete 150 mm width can protect from fire for 4 hours.

TRANSPORTATION SAVINGS
Favorable combination of weight, volume and packaging makes foamed concrete blocks convenient for transportation and allow use motor or railway transport.

VARIETY OF USAGE
It is used for producing construction blocks, thermal and acoustic insulation of roofs, floors, warming of pipes, production of collapsible blocks and panels of partitions in buildings, as well as floors and basements foamed concrete of higher density. So, if you have the equipment for producing foamed concrete you can offer in the market various products and will have big competitor advantage.

 

When comparing foamed concrete with other materials, one must keep in mind that:

  1. it is ecologically clean, breathes, uninflammable
  2. easy to produce in steady-state conditions as well as on a construction site
  3. is produced from components available in any region
  4. 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