Production of autoclave foam concrete

Because of its exceptional thermal insulation qualities and lightweight design, autoclave foam concrete is a highly adaptable and long-lasting construction material. Owing to its low cost and ease of handling, this kind of concrete is frequently used in building.

A slurry is made by combining cement, lime, sand, water, and an expanding agent during the autoclave foam concrete production process. Following that, this mixture is poured into molds, where it expands and solidifies to form panels or blocks. The autoclaving step, in which the material is exposed to high-pressure steam to increase its strength and stability, is crucial to its special qualities.

Anyone working in construction or manufacturing building materials needs to understand how autoclave foam concrete is made. This post will walk you through each step of the procedure while stressing the advantages and crucial factors to take into account when utilizing autoclave foam concrete for a variety of construction projects.

Fields of use

Autoclave foam concrete has undergone extensive testing and experience in our nation. For instance, if a brick wall and an autoclave foam concrete wall are compared, it is evident that the house will be nearly five times warmer with the second option. These concrete blocks are created by hardening a unique mixture. This mixture consists of sand, cement, foam, and water. The air within the block is the primary factor responsible for this product’s low weight.

Until recently, the autoclaved product was exclusively utilized as a roofing insulator; on occasion, it was even employed in the building of industrial facilities. Foam concrete has only been used in private construction for the past 20 years. This building material is used to construct more comfortable residential structures.

The material known as non-autoclaved foam concrete is strong, inexpensive, and safe for the environment, much like autoclaved foam concrete. These products are most similar to natural wood in terms of characteristics, but they stand out for being more resilient to fire. In certain countries, foam concrete is referred to as "bioblocks" because only eco-friendly materials are used during production. This material can be painted, plastered, or trimmed however you like. The production of a wide range of building materials is attractive because it offers a genuine chance to obtain the necessary specific gravity, strength, fire resistance, shape, and size.

This product has dual uses: insulation and structural use. When it comes to longevity, foam concrete is preferred over mineral wool or foam plastic because the latter lose their properties over time.

Characteristics of autoclaved foam concrete

Durability

The strength of autoclaved foam concrete is one of its primary features. It is nearly impervious to outside influences, never wears out, and has stone-like durability. Its low weight and higher resistance index allow it to be used in the construction of buildings with low bulk densities, which greatly boosts the box’s thermal resistance. In contrast to materials like foam and mineral wool, these materials only get stronger and more thermally insulating over time.

Thermal insulation

Foam concrete homes have a higher thermal resistance index, allowing them to retain heat and potentially reduce utility costs by up to 40% over time. Quite often, even more insulation is not needed.

Thermoregulation

A house made of such material can be kept warm in the winter and cool in the summer. Moreover, it doesn’t mind high humidity, which lets you create the perfect microclimate inside the structure.

Quick installation

Buildings can be constructed considerably more quickly thanks to the product’s greater volume, low weight, and low density compared to brick. Processing is simple enough that you can handle all required installation and finishing tasks.

Soundproofing

Any noise can be absorbed by foam concrete, which also prevents echoes from being produced inside the space.

Ecological cleanliness

When in use, this product is most like a tree in terms of its characteristics rather than being able to distinguish between harmful substances.

Economy

Compared to other materials, foam concrete requires significantly less work because of its size. Since building is already an expensive hobby, this enables significant savings.

High level of fire resistance

These types of building materials are very effective at preventing the spread of fire.

Pros and cons

Apart from the aforementioned benefits and attributes, foam concrete also offers additional advantages:

• Light weight. Thanks to this advantage, it is easy to transport and lay. As an addition, it does not require the construction of a foundation.
• A wide range of application options. In addition to solid foam concrete, there is also its liquid analogue. Using various forms, it can be given any configuration.

Nevertheless, the material has drawbacks in addition to its long list of benefits. This includes shrinkage and the capacity to absorb moisture first. This occurs as a result of the manufacturing processes.

Varieties

This kind of building material can be categorized into a sizable list of types based on a multitude of differences. The primary distinctions that categorize it are as follows:

• By binder component. In order to produce an autoclaved product, gypsum, lime, and less often cement are used as a binder.
• By siliceous substance. Quite often, ash, slag and sand are used as an additive in the production of foam concrete.
• By the type of hardening of foam blocks (steaming, heating with electricity, other types of heating).

Technology

The key components of autoclave production technology are production at a specific temperature and pressure and the addition of sand to the main solution in place of cement. Using this manufacturing method results in nearly double the amount of cement being used, improved characteristics, and faster technological advancements. This kind of production invariably results in a strong adhesion between all of the particles. And doing so enables you to produce a material that is more resilient and experiences little shrinkage in use.

In order to create foam concrete blocks, you must mix cement with a number of other ingredients. These additives are essential for both the material’s formation of a particular cellular structure and for quick production. The product’s final saturation, strength, and mass are all impacted by this technological process. Using specialized hoses, a solution with the necessary homogeneity and consistency is poured into an autoclave. The device maintains the specifications required for the proper production of blocks. There should be about 190C in the air. One MPa of pressure. There must be water vapor present.

The importance of the additional components is paramount. After all reactions, aluminum powder produces a robust material that stops the block from shrinking in the future. Additionally, compared to other production methods, the product’s autoclave curing helps to create a more durable material.

The necessary strength is achieved in two or three days following the full technological process in the apparatus, and it is significantly higher than that of a product that was naturally dried for a month. This method of production results in the formation of a unique silicate that cannot be obtained in any other way, but it also reduces the amount of cement used and the bulk density of the block. Additionally, equal parts of cement and sand must be added if the material’s quality needs to be further improved.

In order to produce lightweight, long-lasting building material, a precise process involving the mixing of raw materials such as cement, lime, and sand with water and an aerating agent is followed by curing in an autoclave. This process produces a product with superior insulating qualities, which makes it perfect for construction that uses less energy.

Making a mixture

For grinding, quartz sand is delivered from the storage. You can grind dry or wet. In the event that the dry approach is selected, quartz sand is dried in a designated chamber until the humidity indicator reaches a maximum of two percent. It is then fed into the drum mill only after this. Solids are to be ground in this kind of mill. When cement and sand are ground together, the product will be of the highest quality. This kind of foam concrete will last a long time.

The quartz sand is fed into the drum mill right away if the wet method is selected, but water is also added. Consequently, a sand mixture is produced and put into a designated tank. It will then enter the concrete mixer after first going through a pump-operated dispenser. Sand must be continuously stirred into the mixture to prevent it from settling. The most popular method for grinding sand in autoclave production is the wet method.

Particularly as a cost-effective and adaptable building material is autoclave foam concrete. Its manufacturing process produces a robust and lightweight product through careful mixing, autoclaving, and curing. It is therefore a great option for a range of construction applications.

Superior thermal insulation qualities are one of the key advantages of autoclave foam concrete. It lessens the need for large-scale heating and cooling systems by assisting in the maintenance of comfortable indoor temperatures. Furthermore, by reducing noise pollution, its sound insulation qualities improve the quality of life.

Additionally, the environmental impact of foam concrete produced by autoclaving is minimal. Compared to traditional concrete, it requires less energy to produce, and it frequently contains recycled materials. Because of this, it is a more environmentally friendly choice for developers and builders.

To sum up, autoclave foam concrete is a novel material that blends sustainability, strength, and insulation. Because of its special qualities, it is a desirable choice for contemporary construction projects, helping to create more environmentally and energy-friendly buildings.

Video on the topic

Production of autoclaved aerated concrete at the HESS AAC plant

Demonstration of the production process of autoclaved aerated concrete

Autoclaved aerated concrete plant. Production process of aerated concrete block.

Autoclaved aerated concrete | Made in KZ