Composition of foam concrete and foaming agent for it: technology and recipe

Combining the lightweight qualities of foam with the durability of concrete, foam concrete is an inventive and adaptable building material. It is a great option for a range of construction applications, from insulation to lightweight structural elements, thanks to its distinctive structure. Effective utilization of this material requires an understanding of its composition and the function of foaming agents.

Cement, water, and a foaming agent are the main ingredients of foam concrete. Water helps to facilitate the mixing process, while cement serves as the binding agent. The primary component that adds air bubbles to the mixture and gives foam concrete its unique lightweight and insulating qualities is the foaming agent.

A particular technology and recipe are needed to create foam concrete in order to guarantee the ideal ratio of strength to lightness. When the foaming agent is properly mixed, it produces a stable foam that easily combines with the cement and water mixture. The material produced by this process is not only simple to work with, but it also provides superior acoustic and thermal insulation.

Understanding the ingredients of foam concrete and the technology that goes into making it can help you create new possibilities for your projects, whether you’re a builder searching for an economical and effective material or a do-it-yourself enthusiast interested in cutting-edge building methods. This article explores the specifics of the composition of foam concrete and offers advice on how to use the proper foaming agent to produce high-quality foam concrete.

The term foam concrete

A material that has just started to be used extensively is foam concrete. Though known earlier, it gained widespread popularity in the 2000s and 90s of the previous century.

Because it is comparatively inexpensive, has good thermal insulation qualities, and can be used to make small quantities of products and structures, this material is widely used today.

Let’s define the terms first:

• It is customary to distinguish between foam concrete and foam silicate. These are similar, but completely different materials. By definition, concrete is a mixture of filler and binder, so both materials fit this name. But it is customary to consider foam concrete only as mixtures based on cement, which can harden under normal conditions.
• Foam silicate is produced on the basis of lime and sand, and requires autoclaving to acquire the necessary characteristics of a building material. Although, to be fair, we note that the composition of foam concrete blocks is often treated with high-pressure steam to accelerate hardening in industry, and lime mixtures without steaming can achieve the required strength and water resistance in several decades.
• It is also necessary to distinguish between foam and aerated concrete. In the latter, the porous structure is formed due to the chemical reaction of the components of the mixture, the air cavities are not closed and smaller in size.

Kindly take note! Aerated foam concrete is a mixture of materials. Both techniques are applied in them to create pores. Cellular lightweight concrete based on a cement binder is what we refer to as "foam concrete." The low thermal conductivity of the material is attained because closed pores occupy the majority of the volume of the concrete, as seen in the picture above.

In contrast to porous silicate products, foam concrete becomes stronger over time rather than collapsing at high humidity. Because of its closed pores, which prevent water absorption, it is more frost-resistant than aerated concrete.

Calculation of the number of foam blocks

Choosing the block size, LxHxD

Total length of walls, meters

Average height of walls, meters

Total area of ​​window and door openings, m2

Calculate

m 3pcs.m 3pcs.

Foam concrete technology

1. Classic — a mixture of water, cement and sand is prepared, to which ready-made foam is added, after mixing the composition is formed.
2. Dry — dry cement mixtures for foam concrete are fed into the foam. The moisture necessary for mixing the cement is contained in sufficient quantities in the foam.
3. Cavitation — ​​the foam is not prepared separately from the mixture. Dry components, water and foaming agent, are mixed in one sealed container, into which air under pressure is supplied for intensive formation of bubbles.

Since the final two approaches are limited to factory settings, we will focus on traditional technology going forward.

Foam concrete composition

Foam concrete must contain the following four essential ingredients:

Furthermore, a variety of additives can be used, such as super plasticizers, modifiers (like sulfoaluminates, which lessen shrinkage), pigments for different coloration of the material, hardening accelerators, negative temperature work, etc. Additionally, fine ash is added, which raises the aggregate packing density and, as a result, strengthens concrete while using less cement.

The addition of fiber from polypropylene or other materials, which reinforces foam concrete and boosts its strength by nearly a quarter, is another way to increase strength. Let’s look at the specifications for each part individually.

Cement

• There are no special requirements for this component – except, of course, quality (compliance with standards) and shelf life. Both Portland cement (designated as PC) and slag Portland cement (respectively SPC) can be used.
• No special high-strength cement is required, the most common grade 500 (M500) is sufficient. The same can be said about additives – their percentage is designated after the grade and the letter D, for example M500D20 contains 20% additives. The only exception is when cavitation technology is used to prepare the mixture – in this case there should be no additives (D0).
• Therefore, you should not overpay for pure Portland cement, you can take a cheaper one with additives or SPC. If you do not need a grayish surface, but a pure white one, or you are going to paint a product or structure by introducing a pigment, then for an accurate color it is advisable to use white cement (BC).

Note: Generally speaking, cement has a guaranteed shelf life of no more than six months, depending on how it is packaged and stored. Once it expires, the cement loses its ability to strengthen brands. Don’t purchase it beforehand.

Filler

It doesn’t require any special requirements, just like cement does. The sand used is regular construction sand free of dust and contaminants.

However, using filler with a lot of large fractions over 1.5 mm is not recommended because it will negatively impact the foam bubbles that form. Washed fractionated sand from crushed screenings is the best choice.

Water

To prepare the foam and mixture, use clean drinking or industrial water free of suspended particles and foreign materials that have dissolved. When water is heated, some foaming agents perform better. A minimal amount of rigidity is also desired.

Foaming agents

• The task of the foaming agent is to create a framework for the block structure and hold it until the cement paste gains the required strength, while retaining moisture for the hardening of the mixture. In essence, these are the same surfactants (SAS) that are used in detergents.
• Both natural substances, so-called protein or protein compositions, and synthetic foaming agent for foam concrete created artificially are used. The strength of the material depends on them to some extent, since they affect the water-cement ratio.
• Until recently, protein compositions were considered the best, but today synthetics are superior to them. It forms a more stable foam, does not interact with additives to concrete – and besides, its consumption (and therefore the cost of the material) is less. But most manufacturers use natural substances, since this solves the issue of environmental safety of construction.

By the way, animal blood was utilized as a protein foaming agent for foam concrete in the early trials on the material’s preparation.

A foaming agent, fine sand, water, and cement are mixed to create foam concrete, a multipurpose building material that has a bubbly texture and is lightweight and insulating. The formation of the air bubbles that give foam concrete its distinct characteristics is largely dependent on the foaming agent, which is frequently a synthetic or protein-based material. Comprehending the appropriate ratios and mixing techniques for these components guarantees the creation of premium foam concrete that is long-lasting, energy-efficient, and appropriate for a range of construction uses.

Mixture recipe

The materials used in the production of foam concrete are chosen based on the qualities that the material must have. It is typical practice to separate foam concrete into grades based on variations in thermal conductivity and strength. The grade for foam concrete is denoted by the letter D and represents density rather than compressive strength.

For information, foam concrete grade D800 and higher is regarded as structural, while grade 400 and lower is only insulating. Intermediate grades are thought to provide both thermal and structural insulation.

The following are the approximate attributes of the grades:

Grade	Thermal conductivity	Strength, MPa
D200	not standardized	0.005
D300	not standardized	0.008
D350	7.5-7.8	0.009
D400	8.9-9.1	0.01
D500	12.5-13.5	0.012
D600	15-17	0.014
D700	23-25	0.018
D800	26-28	0.021
D900	33-37	0.024
D1000	48-52	0.029
D1100	62-66	0.034
D1200	87-93	0.038

Advice: Unless a specific frame is provided for this purpose, bear in mind that the wall bears not only its own weight but also the load from the ceiling and roof when selecting a brand of foam concrete for a home.

In industrial settings, the mixture’s composition is determined through laboratory testing and computations involving all of the foam concrete’s constituent parts. A calculation method could be provided, but it would need specific technological knowledge.

As a result, using pre-made recipes is simpler, and in most situations, a slight variation in features is irrelevant. As a result, we will provide an approximate composition and proportions of foam concrete.

Recipe for protein foaming agent and M500 cement foam concrete:

Foam concrete grade	D400	D600	D800	D1000	D1200
Sand, t	—	0.21	0.42	0.59	0.78
Cement M500, t	0.3	0.31	0.32	0.35	0.36
Water for mixing the mixture, l	115	115	125	125	145
Water for diluting the foaming agent, l	60	55	45	41	34
Foaming agent, g	1500	1300	1200	1000	910
Volume of pores in finished foam concrete, %	75-85	65-75	60-70	50-60	40-50
Foam concrete yield, t	0.47	0.68	0.9	1.1	1.3

This is an approximate amount of the foam concrete mixture; modifications are needed if additional materials are used. Additionally, in order to prepare the solution according to the plasticizer’s instructions, the amount of cement and water must be decreased.

Component	Description
Portland Cement	The main binder, providing strength and structure.
Sand	Filler material that adds volume and reduces cost.
Water	Activates the cement and helps create a paste.
Foaming Agent	Creates bubbles in the mixture, giving foam concrete its lightweight and insulating properties.
Fly Ash	Optional component that improves workability and can reduce costs.
Admixtures	Optional additives to enhance certain properties, like setting time or strength.

Because of its good insulation qualities and light weight, foam concrete is a useful building material. The principal ingredients of this mixture are sand, water, cement, and a foaming agent. The foam structure that gives concrete its distinct qualities is largely produced by the foaming agent. In order to produce high-quality foam concrete, it is imperative to comprehend the proper combination and the role of each component.

In order to produce a stable foam, the foaming agent and water are combined in the foam concrete technology. The cement mixture is then combined with this foam. The end product is a substance that is simple to pour into molds and shape as required. For the final product to be strong and long-lasting, the foam’s consistency and stability are essential.

Selecting the appropriate foaming agent is essential. It ought to have the capacity to produce a consistent, sturdy foam that can sustain the cement mixture and endure mixing. Foaming agents come in a variety of forms, each with unique benefits. Achieving the required qualities for the foam concrete can be aided by varying the mixture and testing various agents.

Although foam concrete’s composition and technology are generally simple, attention to detail is necessary. Successful outcomes can be achieved by carefully balancing the ingredients and comprehending the function of the foaming agent. Foam concrete is an excellent option for many construction applications due to its lightweight and insulating qualities.

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