Monolithic foam concrete in permanent formwork – or how to quickly and efficiently build a budget house

A house’s construction can be both an exciting and intimidating undertaking, particularly when juggling quality, timeliness, and finances. Using monolithic foam concrete in permanent formwork is one creative solution that has grown in popularity. This approach results in long-lasting, energy-efficient homes while streamlining construction and cutting expenses.

Building materials that are strong, lightweight, and adaptable include monolithic foam concrete. It produces a seamless, integrated structure with minimal requirement for conventional building materials and labor when paired with permanent formwork. This combination makes it possible to build a home quickly and effectively, which makes it a great option.

Foam concrete is poured into formwork that has already been installed and is still a part of the structure during the process. By doing away with the necessity to remove and dispose of formwork, this method saves time and lowers waste. Moreover, foam concrete’s insulating qualities lead to reduced energy costs and a cozy interior atmosphere.

This approach can save builders a lot of money if they follow it. It’s an appealing choice for anyone trying to build a cheap house without sacrificing quality because of the lower labor costs, faster construction, and less reliance on pricey materials.

This post will discuss the advantages of using monolithic foam concrete in permanent formwork, describe its operation, and offer helpful advice for anyone thinking about using this cutting-edge building method. Whether you’re an experienced builder or a first-time homeowner, you’ll get insightful advice on how to design a sturdy, affordable, and energy-efficient house.

Properties of monolithic foam concrete

Even though foam concrete serves primarily as insulation in monolithic construction, it’s still important to understand its fundamental qualities and requirements. especially if you plan to use this technology to build a house with your own hands.

Foam concrete with a density of D250 to D800 is used, depending on the formwork that is used. These grades may also differ based on the specifics of the project. Given that the hardened solution inside the formwork cannot be removed or replaced, it is imperative that the commercial foam concrete be of high quality.

The following are the primary causes of low-quality foam concrete production:

• unstable foam;
• too much/little foam in the concrete solution;
• dirty sand;
• low-grade cement;
• the difference in water temperatures in the solution and in the foam.

The only way to determine how to get the "right" foam concrete is to have a thorough understanding of these issues. Let’s discuss a few solutions to these issues.

However, they can’t always "work" in the same way. There are other adverse circumstances in each particular situation that must also be considered.

Improving the quality of raw materials

I want to start off by cautioning you that foam concrete is a pretty erratic substance.

Additionally, you must begin the selection process with the primary materials, which need to be examined in a lab to ensure that they meet quality standards, in order to ascertain what it dislikes:

• Cement M400D0 or M500D0 with the 1st activity group during steaming. If, according to the results of the study, it turned out that the purchased batch of cement has the second or even third activity group, then you need to urgently reconsider the selection of the composition – namely, increase the amount of cement. If this is not done, hardening will take much longer, and during this time the foam in the solution will begin to collapse. This means that shrinkage, defects, losses are inevitable.

From the time the sample is received until the protocol is issued, such a test takes roughly a day to complete. In order to "rebuild" the foam concrete composition selection in a timely manner.

Everything is much more complicated when given the strength of cement. Naturally, you can obtain the results in three days, but they are not trustworthy. Gostov exams run for 28 days. The quality of the foam concrete itself will likewise degrade if the cement’s strength is inadequate. Thus, test every type of cement that is available in your area beforehand, and choose the best quality.

• River sand with a size module from 1 mm to 2.5 mm should be clean, at least without commentary clay inclusions and bunched trash. Clay reduces the "power" of cement. Garbage can disable the equipment if foam concrete is poured into the formwork using a heroor pump. His blades will be irrevocably lost. Therefore, it is recommended to sift the sand in front of each batch on a large technical sieve or a conventional grid.

Another important factor is the moisture content of the sand, which is what the solution will receive during manufacturing. This implies a rise in the water-to-cement ratio, which is detrimental to concrete, as is well known. As a result, the composition needs to be adjusted once more, this time only with regard to the amount of water in the solution.

• The water must be absolutely clean without any inclusions or other debris. In principle, as for a regular solution. But in foam concrete it plays a special role – the difference in water temperatures in the solution, in the foam and the environment leads to the destruction of the cellular foaming structure. Therefore, it is better and cheaper to heat the water than to get low-quality concrete.

These, in theory, are the primary variables that can be controlled in "field" settings for foam concrete components, allowing for quick compositional changes to prevent defects.

"Bad" foam and how to deal with it

And now for the painful subject: foam. For any worker dealing with foam concrete, this is the first challenge they encounter. And for some people it haunts them nonstop. How should I handle it?

Let’s look at the primary issues that foam concrete producers frequently face:

• The concentrate is not suitable for the generator type. When purchasing equipment, be sure to clarify this nuance.
• Too much water in the foam.
• Perhaps the pressure in the pump is not adjusted.
• If your foam is generated under pressure through a metal pipe with filler, it may be worth replacing it. The most profitable material for this role is small-diameter plastic balls, for example, bullets for a children"s gun. Such a part of the generator must be constantly washed with a cleaning agent.
• Perhaps the air temperature is too low.
• Be sure to weigh the foam. Its weight should be equal to, or its value should be as close as possible to the manufacturer"s data.
• Do not use additives for concrete. They only extinguish the foam.

Once you have a few good mixes, you should be able to tell "by eye" what kind of porous filler you have.

Kindly take note! Foam manufactured on SDO can be stabilized using a single "bearded" technique. First, quench the fluff to a density of 1.055–1.005 kg/l in the solution. This represents a 10% solution, roughly. The resulting lime milk should be added to the concentrate at a volume of about 70%. However, keep in mind that the amount of water in the foam is pre-calculated to include such an additive.

A comparable recipe will aid in producing a mixture with more stable foam. Don’t go overboard though. In concrete, too much lime is ineffective.

Formwork "with three heads"

As was previously mentioned, foam concrete may require different permanent formwork. It varies in that finishing work on the outside and inside can be done at the same time. On the other hand, foam concrete removable formwork is more affordable, and this will definitely be the case in the future when the matter of facade cladding comes up.

The choice of permanent formwork is made based on the anticipated house’s floor plan and the local climate. But whatever you choose to concentrate on, keep in mind that the basic idea remains the same. The only aspects of the formwork that vary based on type are its stages.

Brick sandwich

Brick permanent formwork is undoubtedly the most dependable and long-lasting option for monolithic foam concrete. In contrast to block construction, this technology allows the construction of even multistory buildings.

Because foam concrete acts as an insulator in this way, it absorbs small brands according to density. Because everything is dependent on the thermal engineering data of the construction region, it is challenging to navigate by the thickness of such walls.

One-sided or double-sided brick well masonry can be used to create this type of formwork. In the latter instance, the inner side of the formwork is composed of a variety of slab materials with increased density and rigidity.

Take note! Bricklaying is a labor-intensive trade that calls for a certain level of expertise. Hiring professional masons is the best option if you have never done this kind of work yourself. Anything is preferable to tearing down the existing wall and starting over.

This monolithic construction technology’s greatest benefit is that interior rough finishing and facade finishing are completed concurrently with wall construction. Consequently, the ostensibly needless expenses associated with acquiring and installing bricks are warranted and significantly less than those incurred when installing extra external cladding.

How to install brick permanently You can learn more about formwork for pouring foam concrete in the video below.

Lightweight option

There is total flexibility in selecting permanent foam concrete formwork thanks to a wide range of contemporary sheet materials:

• cement-bonded particle boards;
• plywood;
• OSB sheets;
• moisture-resistant or fire-resistant gypsum fiber board, but this is an unreliable option, since under the pressure and temperature of foam concrete, the sheets can warp.

Additionally, a composite is frequently used, with the inner portion of the formwork made of sheet and the outer part made of concrete facing material. It is faster, of course, and doesn’t require any more facade work.

While using sheet materials for the entire formwork allows you to "stretch" the construction costs and do the cladding gradually, this method is more costly. This is a very profitable option for a lot of people.

Lego constructor

Additionally, there are unique permanent formwork systems for building foam concrete monoliths. These are foam blocks made of hollow polystyrene that have been strengthened with a polypropylene frame and particular fasteners.

They are simple to assemble and incredibly light. They were dubbed "Lego blocks" by our builders. They are put together like a builder, in fact.

These blocks don’t offer facade cladding all at once. The house is then qualitatively warmed by them. However, you ought to consider your options before choosing such formwork. Rodents, after all, merely adore shredding these kinds of materials for breakfast, lunch, and dinner.

The creators of these non-removable forms, however, promise that problems of this nature are not anticipated. Furthermore, the reasonably low cost of this formwork is a pleasant surprise.

Additionally, the material used in monolithic construction comes in a different variation. Using this technology, arbolite hollow blocks are utilized. They have two sizable holes and are a typical product.

Both longitudinal and horizontal reinforcement are possible for a system like this one. Additionally, it works well with foam concrete monolithic. Ordinary concrete may also be used as a "filling".

Budget-friendly home building is being revolutionized by monolithic foam concrete in permanent formwork, which provides a rapid, effective, and economical solution. This technique allows for quicker build times and lower labor costs by combining the durability and insulation of foam concrete with the ease of use of permanent formwork. It’s an affordable option for many aspirant homeowners, providing them with a sturdy, energy-efficient home without breaking the bank.

Calculation of the composition of concrete

Building a foam concrete monolith

Do you want to use an adult building set for playtime? We provide a brief report on the use of permanent block formwork in the building of a house. Those who don’t mind taking chances are the target audience for our instructions. So, how about we get started?

Basis

The most popular foundation device for this kind of permanent formwork is a slab or tape. It’s all project-specific. The horizontal frame device is the only thing that sets foundation works of this format apart from regular ones.

It is reinforced with ribs that have a diameter of 12 to 16 mm. Throughout the entire perimeter, the rods are fastened to the reinforcement frame in steps of roughly 30 cm. You can start more work after the foundation has held and conventional waterproofing has been completed.

Reinforcement

Such a formwork system is strengthened by vertical reinforcement, which happens less frequently horizontally. Strong spacers and fastening mechanisms on the blocks themselves eliminate the need for a longitudinal frame. This reinforces the foam concrete even more.

Simply said, the rods are progressively added based on how smoothly the walls develop.

Installing the formwork

The most exciting part is about to begin: formwork installation. These blocks, as you have already observed, are fastened in a manner akin to the reliefs found on a standard construction set. That’s not all, though. The formwork has unique fastening spacers installed in order for the walls to withstand the pressure of concrete; these spacers are visible up close in the picture below.

Every manufacturer uses a different method to install formwork. In one, the blocks must be installed after they are fastened, not at the beginning; in the other, the exact opposite is true. The most significant thing, though, is that up to 100 m2 of walls can be filled in a day with little labor because of how simple it is to install such formwork.

These blocks are also incredibly simple to cut, and you can use them to make walls in any shape you choose. The video in this article provides a detailed example of how to assemble such formwork.

Concreting

Foam concrete is poured into permanent formwork in phases.

Recall that better enclosing structures are achieved the faster walls are constructed monolithically.

• Therefore, they try to pour foam concrete into the formwork of the first floor in one day. And this becomes real due to the simplicity of assembling the formwork and the short time spent on mixing foam concrete.

• In this case, calculate the prepared volume of foam concrete and formwork. Just pouring foam concrete should occur as quickly as possible, until the foam begins to collapse.
• If there is a delay, which can be caused by the installation of additional formwork, part of the mixture in the mixer will most likely be unsuitable for further work.
• How to pour foam concrete into formwork? Yes, it"s very simple. Using a gerotor pump and a hose. But just keep in mind that when using an additional screw transmission, the foam can collapse and there will be additional losses of the solution. How monolithic foam concrete pouring of foam concrete into formwork is carried out, the video below will tell you in more detail.

Topic	Monolithic foam concrete in permanent formwork – or how to quickly and efficiently build a budget house
Advantages	Cost-effective, fast construction, good insulation
Materials	Foam concrete, formwork panels
Steps	1. Set up formwork 2. Pour foam concrete 3. Let it cure
Timeframe	Can be completed in a few weeks
Durability	Long-lasting and strong structure
Insulation	Excellent thermal and sound insulation
Eco-friendly	Uses fewer resources compared to traditional methods

The use of monolithic foam concrete in permanent formwork presents a novel way to swiftly and effectively construct inexpensive homes. This technique creates a sturdy, long-lasting structure that is energy-efficient by fusing the ease of use and insulation of foam with the strength and durability of concrete.

The speed of construction is one of the biggest benefits. There is no need for extra steps to remove or disassemble the formwork because it is left in place, which saves time and labor costs. Incorporating foam into the concrete mixture not only streamlines the construction process but also improves the final structure’s thermal characteristics, resulting in a more comfortable and energy-efficient living environment.

Another important advantage is cost-effectiveness. With permanent formwork, monolithic foam concrete lowers costs without sacrificing quality by requiring less labor and materials. This makes it a great choice for anyone on a tight budget who wants to build a home or a business.

Apart from its pragmatic advantages, this construction method also promotes sustainability. The environment benefits from the increased insulation since it uses less energy for heating and cooling. Additionally, because of the structure’s longevity and durability, fewer resources will be required for upkeep and repairs over time.

All things considered, monolithic foam concrete in permanent formwork is a clever, cutting-edge option for anyone wishing to construct a cost-effective, reliable, and energy-efficient house. Its ability to blend cutting-edge construction techniques with useful advantages makes it a desirable option for a variety of construction projects.

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