Cellular Lightweight Concrete

Construction Made Green

• Midscale Production of Cellular Lightweight Concrete using wet mixtures of agents as cement, fine sand, fly ash, organic and inorganic fibers etc.

• Produces CLC at various densities from 150 up to 1400 kg/m3

• Cast-in-Situ functionality with pumping the required mix along with the foaming agent to location of casting (up to 20 m elevation and 50 m distance)
• Product variety: specific foaming agent for roofing, flooring, block production, cast in situ walls

• Innovative foaming agent technology protein based with enzymatic active components, developed especially for the building material industry.

• Variable compressive/tensile strengthdue to its closed cellular structure, becomes a function of density, moisture, mix proportion, chemical and physical characteristics of components materials and curing method. High percentage of foam in the mix reduces the compressive strength in favor of lighter weight and better insulation characteristics.

• Cellular concrete is concrete that has been manufactured to contain lots of closed air pockets. Lightweight and fairly energy efficient, it is produced by adding a foaming agent to concrete.

• Fly ash (residue left from burning coal, which is collected on an electrostatic precipitator or in a baghouse) is also introduced to improve the quality and durability of the concrete mix. Fly ash improves concrete’s workability, pumpability, cohesiveness, finish, ultimate strength, and durability as well as solves many problems experienced with concrete today–and all for less cost.

• CLC has a moderate embodied energy content and performs well as thermal and sound insulation, due to the aerated structure of the material and its unique combination of thermal insulation and thermal mass. It is light, does not burn, is an excellent fire barrier, and is able to support quite large loads.

• The gas used to ‘foam’ the concrete during manufacture is hydrogen formed from the reaction of aluminum paste with alkaline elements in the cement.

• Firstly, the mix composition of cement / sand / water / fly ash according to specification has to be chosen. After batching the basic ingredients, the Foaming Agent is introduced to the mix which then can be poured on situ directly into structural elements or into panel/block molds of virtually any shape or size. The Aerated Lightweight Concrete Mix normally cures in open air within about 24 hours.

• The foam enables the slurry to flow freely due to the thixotropic behavior of the foam bubbles, allowing it to be easily poured into the chosen form or mold. The viscous material requires up to 24 hours to solidify (or as little as two hours if steam cured with temperatures up to 70 °C to accelerate the process depending on variables including ambient temperature and humidity. Once solidified, the formed produce may be released from its mold.