How to make a foaming agent for foam concrete with your own hands

Making foam concrete at home can be a satisfying project, particularly if you want to experiment with different building materials or cut costs. The foaming agent, which contributes significantly to the process and helps produce the distinctively light and airy texture of foam concrete, is essential.

We’ll walk you through the process of creating your own foaming agent at home using easily accessible ingredients in this guide. You’ll be able to create a foaming agent that enhances the quality of your foam concrete and meets your needs by using basic materials and simple, easy-to-follow techniques.

This realistic approach will equip you with the knowledge and self-assurance to handle your foam concrete projects with ease, regardless of whether you’re a DIY enthusiast or just interested in the procedure. Now let’s explore how to make your own foaming agent and begin experimenting with foam concrete in your own home.

What is this solution?

A material with a cellular porous structure—a result of air bubbles filling the solution—is used to make foam blocks. Combining cement and sand, stable foam is poured into a mold and allowed to solidify.

After mixing, the following material is produced, which has some benefits:

• increased thermal insulation properties;
• reduced cement consumption;
• less weight and savings on foundation, masonry, transportation;
• simple and easy processing;
• strength gained over time;
• eco-friendliness.

The foaming agent itself comes in a variety of packaging options, including barrel, can, and canister, and can be bought already made or concentrated. Additionally, you could make it yourself to save money on production.

Characteristics

Concrete foaming agents can be synthetic or organic. Synthetics are used to make low-quality products and are less expensive than natural products.

The process of creating blocks takes longer when chemicals are used. Foam concrete will have less strength. Efforts to raise quality standards will drive production costs higher and profitability lower.

A large variety of synthetic materials, both imported and domestic, are available in the retail chains of Moscow and other major cities. Online retailers offer the option to make purchases for remote locations.

Foam formers range in price from 70 rubles per kg and up. Synthetics can be used in both traditional versions with a foam generator and barotechnology-based schemes:

1. Barotechnology is a less expensive, simpler process. The basic components of artificial stone – water, cement, sand or ash – are introduced into a sealed mixer along with a foaming agent. Then the pressure in the mixing container increases, at which the composition is mixed. During the stirring process, the solution becomes saturated with air. To accelerate and regulate structure formation, it is possible to use functional additives.
2. A foam generator is needed to make foam separately. It is a container into which the foam former is poured. The composition from it is fed into the mixing chamber, where it is combined with air from a pump or compressor. The emulsion enters the foam cartridge through a nozzle or Laval nozzle, designed to foam the original substance. The output is foam, the quality of which changes due to the adjustment of the valves for feeding the foaming emulsion and air. They are placed in front of the mixing chamber together with shut-off valves.

Organic foaming agents (protein or protein)

They are regarded as additives of superior quality. When they are used, concrete that fully conforms to GOST 25485–89 is produced.

1. Artificial stone is prepared faster.
2. After filling the form, the mass of concrete is more stable.
3. The composition of the blocks is more natural.
4. It is possible to make high-density concrete.

The best option is a natural former, but they cost more. As a result, a lot of building material producers would rather produce the composition and foam-generating devices on their own, or foam generators.

At 20°C, the protein composition "Etalon," for instance, has a density of 1110 kg/m3 and is a dark brown liquid. The composition has a pH of roughly 7, solidifies at -250° C, and remains unchanged upon defrosting. It can be kept in its original packaging for up to 24 months at a temperature between -50°C and +40°C as long as it is kept out of direct sunlight.

Technical foam produced with "Etalon" will have the qualities listed below:

• foaming agents are diluted from 1:60 to 1:40 depending on the desired concentration of the working solution;
• water is used as a solvent;
• foam with a uniform microporous structure is white;
• multiplicity is 7-50;
• 1 kg of foam formation produces 830 liters of foam with a stability of at least 98%.

Composition and varieties

Understanding the composition of foam concrete is necessary in order to make a foaming agent by hand.

Water needs to have surface-active ingredients added to it (surfactants) in order to create a foamed structure. Soap is the most easily accessible and basic type of surfactant. The primary issue with soap compounds is the high calcium content of cement.

Calcium ions will take the place of sodium and potassium ions if you add solid sodium or liquid potassium soaps, which are made by reacting alkali with animal or vegetable fats. As a result, the foam that is produced will quickly collapse and not dissolve in water.

As a result, compounds such as naphthenic or resin, which contain acids rather than vegetable or animal fats, are used to prepare foam for foam concrete. These soaps actually become more foamy in a calcium environment rather than lessening them.

The recipe for the preparation of the foaming agent

It is possible to independently prepare a comparatively small amount of foaming agent for foam generators used in private construction projects.

1. Bone wood glue in the amount of 63 g. It is obtained from waste fish and animal bones, horns or the leather industry. Most often, the glue is produced in the form of granules, which include cysteine, gelatin and collagen. There are also forms of release in the form of scales and powders. The composition is used for gluing wood materials, making chipboard.
2. Caustic soda (caustic soda) – 16 g. The substance is an alkali that dissolves well in water, does not burn, actively reacts with tin, zinc, lead and aluminum, destroys glass, organic contaminants and fats. Used in everyday life, gardening, in the preparation of detergents, to which vegetable or animal fats and essential oils are added. If it gets on the skin, it is neutralized with vinegar.
3. Pine rosin – 60 g. It is obtained from cellulose, tall oil or crushed pine. The substance contains resin and fatty acids, neutral components. The product does not dissolve in water. Used as a solder to reduce surface tension. When combined with organic and mineral substances, soap is formed.

Made on its own, synthetic foaming agent for foam concrete (aerated concrete) is seldom used; it is usually bought pre-made.

Preparation technology

There are multiple steps involved in getting ready the foaming agent:

1. First of all, make "soap". Rosin crumbs and soda solution with a density of about 1.2 kg / dm3 are prepared separately. You will need a fine sieve to sift the crushed pieces of rosin.
2. The resulting grind is poured into a soda solution previously brought to a boil. The mixture is prepared at the rate of 1.5 kg of rosin crumbs per liter of soda. The brew must be constantly stirred. For complete readiness, 1.5-2 hours of boiling will be required.
3. Before using the glue, it is soaked. Take 1 kg per bucket of water and keep for at least a day. To get a homogeneous mixture, the glue is heated to 700 and, stirring, achieve the complete disappearance of solid parts.
4. At the last stage, mix the "soap" and glue at a ratio of 1:6. To do this, cool the soap solution and pour it into the existing adhesive mass.

If premium materials are chosen and manufacturing techniques are followed, the final foam structure will have pores that are no larger than 0.4 mm. The composition should be at a temperature of + 5 °C to + 30 °C in order to work with it.

Making a foaming agent for foam concrete at home may be a fun project that gives you the satisfaction of doing it yourself while also saving money. By using the appropriate materials and a little perseverance, you can create an excellent agent that improves the characteristics of your foam concrete.

Recall that the secret to ensuring consistency and efficacy is to closely adhere to the mixing ratios and instructions. You can customize the foaming agent to fit your unique requirements, whether for small projects or larger applications, by experimenting and improving your formula.

You’ll have no trouble producing excellent foam concrete with your homemade foaming agent. Savor the journey and be proud of the final product’s adaptability and functionality!

It can be rewarding and affordable to make a foaming agent for foam concrete at home. Your concrete will become lighter and more insulating if you make a foam out of easily accessible, basic ingredients. With more control over the foam’s consistency and quality thanks to this do-it-yourself method, you can more easily accomplish the intended outcomes for your remodeling or building projects.

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