Foam concrete installation: selection criteria and operating principles

The construction industry is seeing a rise in the use of foam concrete due to its exceptional thermal insulation and lightweight characteristics. It is imperative to comprehend the selection criteria and operating principles of foam concrete installation, regardless of whether you are constructing a new building or renovating an old one. This adaptable substance can be used in a variety of ways and offers a number of advantages that conventional concrete might not.

A number of factors need to be taken into account when selecting foam concrete for your assignment. The material’s strength, density, and thermal conductivity are important properties that will affect how well the finished structure performs. The type of foam concrete, whether pre-foamed or mixed during application, can also have an impact on the final product’s quality and the installation process.

To ensure a successful installation of foam concrete, it is helpful to understand the underlying operating principles. Cement, water, and a foaming agent are combined in this process to create a material that can be cast into large blocks or poured into molds. The final characteristics of the foam concrete are also greatly influenced by the curing process and the surrounding environment, which can have an impact on anything from insulation effectiveness to durability.

Criteria	Description
Density	Choose the right density of foam concrete based on the load requirements and insulation needs.
Compressive Strength	Ensure the foam concrete has sufficient strength for structural stability.
Thermal Insulation	Check the material"s insulation properties to ensure energy efficiency.
Sound Insulation	Consider the ability of foam concrete to reduce noise transmission.
Moisture Resistance	Look for foam concrete with good moisture resistance to prevent water damage.
Workability	Choose foam concrete that is easy to mix and apply.
Cost	Compare prices and consider the overall cost-effectiveness.

Notes of a technologist

We need to discuss the two primary processes used to make foam concrete in order to comprehend how a production plant operates and what technological features it possesses.

Dry mineralization

Preparing the foam concrete so that cell formation happens as a result of physical processes rather than a foaming agent’s influence is the most economical option.

Although these installations are small in size, using them in a high-pressure tank requires caution.

A pressure unit used to produce foam concrete is the central component of this kind of production line. This is essentially a high-speed, dry mixing mixer that runs at 420 rpm/min. Moreover, the mixture is further mixed while under increased pressure.

Excessive pressure prevents the bubbles in the concrete massif from "opening," preserving their consistent size, shape, and quantity.

It is difficult to maintain the block’s porous structure, which directly affects its consumer qualities.

Dry conditions are used for preliminary intense mixing, which enables the creation of pores with a leveled structure, or roughly equal sizes.

The capacity of the pipeline to supply the finished mixture to a height of up to 10 m and up to 30 m along the strike in the horizontal projection is a feature of lines using dry mineralization technology. This technology is economical when it comes to the price of the necessary equipment. Foam concrete, however, is of very poor quality for several apparent reasons.

Two-stage technology based on a foaming agent

Such a line includes a foam generator as a preliminary technological unit in addition to the mixer. The foaming agent is fed into the low-speed mixer after being activated in the foam generator. The other ingredients for the concrete base are added to the mixer after a dose of foam has been added, and mixing then takes place at 25 rpm/min.

After that, the foamed mixture is poured into molds via pipelines, where the future block is poured and goes through its initial maturation.

Here it is necessary to note a number of advantages that this technology provides to the manufacturer:

• The formation of pores occurs in an absolutely controlled process, which provides ample opportunities for the formation of blocks with a known density, strength and thermal insulation qualities.
• The cells are smaller compared to the use of dry mineralization technology.
• Due to the use of forced rather than natural foaming techniques, the final quality of the finished blocks is higher than those that have passed through foam concrete installations without a foam generator.

The following are some of this technology’s inherent drawbacks:

• Higher cost of the process line.
• Higher cost of the product block, due to the use of a foaming agent as a separate reagent.
• Lower possibilities for transportation by a pipeline system, especially vertically.

Selecting the appropriate type of foam concrete and knowing how to handle and apply it correctly are essential for a successful installation project. The density and thermal characteristics of foam concrete, as well as the optimal methods for mixing, pouring, and curing it to produce a long-lasting and effective finish, will all be covered in this article.

Types of installations for the production of foam concrete

Foam concrete installations are one kind of equipment that is divided into three main categories by modern practice.

Mobile installations

These setups are designed to meet the demands for cellular concrete at the construction site or to produce small quantities of completed foam blocks for small-scale handicraft production. Such apparatus.

Typically, dry mineralization technology is small in size, weighs a manageable amount, uses minimal energy, and requires only one operator for maintenance. A volume of 75 cubic meters per day of completed block should be taken into consideration as the productivity ceiling. A commercial block containing 21 cubic meters is the minimum breakeven point.

The unit can move much more swiftly and easily when it is mounted on a wheeled carriage.

This option is first worth considering if the quality requirements for the final block are not crucial and the equipment’s low cost, light weight, low energy consumption, and numerous options for quick relocation are what matter most to the user.

Stationary units

These units are essentially a full-fledged technological base equipped with a low-speed rotator-mixer and a foam generator. They give you access to a large selection of completed blocks with various nominal strength and thermal efficiency indicators.

It is not always economical to perform such work for stationary units, and it is only appropriate when extremely high volumes are mastered.

With this equipment, 100 cubic meters of commercial block can be produced every day. Because of an order of magnitude increase in productivity, the cost price of a cubic meter of finished product is less than that of mobile units.

Nevertheless, this uses more energy and necessitates the industrial site to have a three-phase power supply, as well as more service staff and in-depth process technology knowledge.

Automatic units with features of a production line

These systems are highly automated production methods that have conveyor lines and control systems for every step of the process, from the time the mixture’s components are prepared until the block gains the ability to be excavated.

Automated lines typically require the use of large, closed spaces.

The distinct zonal division of the entire area into five sections, each with a production profile and area of specialization, should be regarded as a feature of the production lines. Because of the "scaling production" effect, automatic installations have the lowest cost prices and the largest production volumes—up to 160 cubic meters of finished products per day.

Arrangement of operational loading, a crucial requirement for the workshop’s continuous operation in the context of the sale of big quantities of blocks

Large-scale production projects, commissioning, regular maintenance by specialized service units, and operating staff training are all necessary for automatic lines. It’s important to acknowledge that the initial capital investments were substantial.

A lot of thought should go into how bulk components are stored in closed silo-style storage facilities when producing foam concrete in large quantities.

It should be noted that serious consideration should be given to the used equipment segment in the absence of commercial goals for opening, establishing, and expanding production as a business that generates a steady income, and the purchase of the installation is seen as a genuine opportunity to meet your own needs during private construction of a specific object or group of objects. In addition to enabling the actual production of the commodity block, this will enable a significant reduction in the initial start-up capital costs.

Crucial! When buying used equipment, the most important considerations should be its remaining life and technical condition, as well as whether or not it meets the "price-quality" criterion. The implementation of repair and restoration work will neutralize the entire economic effect in the event that there is a significant imbalance in this indicator.

Concrete volume calculator

Additional equipment for the production of foam concrete

Typically, a mobile foam concrete production unit consists of a bar unit, a pipeline system, a control unit, and a safety unit. More productive and stationary units have a foam generator. To provide compressed air to the primary users, a compressor is needed.

Basic requirements for compressors

As a source of compressed air, the compressor needs to fulfill two fundamental specifications:

1. The peak value of pressure on the pneumatic massage must correspond to the indicator of 6 atmospheres.
2. The minimum necessary performance should begin with an indicator of 500 liters per minute.

It is essential to create moisture separators based on intermediate receivers and silicogel cartridges, as well as oil traps based on labyrinth inserts, as supplementary devices to guarantee the pneumatic group’s proper operation.

A specific margin of error must be present in the compressor’s peak pressure and overall performance.

When working with organic foamers based on different proteins, moisture and oil emulsion are crucial. When these parts are used, inventory foam concrete will be identified as beoblocks.

Molds are an equally important additional device because foam concrete can be produced by pouring into a solid mass on site or by molding into a commercial block.

Molds for foam concrete

High-strength plastics and composites, moisture-resistant plywood, and metal can all be used as molds for installing foam concrete blocks.

• Metal molds are made of structural steel grade st 3.sheet thickness of about 3 mm. Metal products are durable, strong and able to withstand temperature fluctuations.

Prefabricated metal molds for foam concrete are heavy and costly, but they are simple to use and long-lasting.

• Plywood products with minimal sufficient strength are attractive due to their budget and the possibility of making them yourself. In addition, routine repairs can be carried out using a simple set of tools, without cutting and welding.

Using large-size molds to pour a block and then cut it to a specific size makes sense in some situations, as seen in the given photo.

• Molds made of composites are still very rarely used in mass production, primarily due to the complexity of manufacturing a matrix and a punch of a mold for their casting from high-strength polymers.

Due to the extremely limited capabilities of the domestic machine-building base, high-precision multi-axis machining centers with large cutting tool strokes along the main axes are needed.

In essence, even a basic mold is an extremely intricate precision component that calls for highly skilled metalworking.

The use of such forms is a very tempting and promising direction because it solves several pressing issues related to the turnover and use of forms:

• Makes them cheaper.
• Allows to produce molds from secondary raw materials.
• Makes it possible to have a reserve of molds and organize production in several shifts.
• Simplifies preparatory activities for pouring, since when using some types of polymers, there is no need to lubricate the mold, due to the extremely low adhesion of the surface of such materials to concrete.

Useful little things

You should be aware of several other important points even though, as you are aware, there are no small details in any business.

The quality of the sand and cement used to produce foam concrete affects the equipment used in that process. As a result, enriched quartz sand and tested Portland cement grade 500 must be used in production as a requirement and quality assurance.

Even with outdated technology, quartz sand greatly raises the standard of the commercial block, which is just beginning to gain traction.

The use of premium additives is a condition that is equally important. Specifically, the BIO-NM modifier based on C-3 concrete plasticizer must be used to guarantee the finished block’s resistance to frost. By adding aerating additives like BIO-Lux, Siplast, and PVD-3 to the sealing mixture, more air entrainment can be obtained.

Do it yourself

An entirely feasible option is to install foam concrete yourself if you have the necessary tools and know-how. For additional details on the fundamentals of manufacturing as well as the finer points of the technical aspects of the procedure, view the video included in this article. It can also function as a form of guidance.

Separately, I would like to point out that a do-it-yourself installation can significantly lower a crucial indicator like the product’s price. A do-it-yourself foam concrete production unit typically needs metal cutting, welding, turning, and milling operations, mechanical assembly for the final product’s installation, as well as startup and adjustment procedures.

When producing foam concrete, special attention should be given to a crucial component such as a do-it-yourself bar unit. The bearing unit needs to be built to function in situations where there is an irrational distribution of radial load at higher mixer tank speeds and higher cavity pressure.

Domestic manufacturers

When there is a significant fluctuation in the value of major currencies, consumers tend to prioritize domestic products.

The most typical ones are:

• installation for the production of foam concrete bas 130;
• in the southern regions, the installation "strom penobeton 250" has become widespread;
• the installation for the production of foam concrete "pbs 2 06" is also gaining popularity.

For those seeking to balance ease of use, affordability, and efficiency in construction, foam concrete is a great option. It is an adaptable material for a range of construction projects due to its lightweight design and strong thermal insulation. To guarantee the best results, it’s critical to take into account variables like density, strength, and the intended application when choosing foam concrete.

The longevity and quality of the construction can be greatly impacted by an understanding of the operating principles of foam concrete installation. Important steps in the process include careful application, accurate additive dosage, and proper mixing. You can create a structure that satisfies your needs and is dependable and long-lasting by paying attention to these little things.

All things considered, foam concrete has many advantages, including affordability and ease of handling. You can fully utilize this material’s potential in your construction projects by choosing the appropriate type and adhering to the recommended installation procedures. In order to construct sturdy and effective structures, foam concrete can be a useful tool for both professional and do-it-yourself builders.

Video on the topic

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