Aerated concrete and foam concrete are frequently discussed in relation to building materials. While both materials are now commonly used in construction, they aren’t exactly the same. Making the ideal decision for your project can be facilitated by being aware of their distinctions.
Foam concrete is renowned for being user-friendly and lightweight. It is made by incorporating tiny air pockets throughout the concrete mixture by adding a foaming agent. Because of this, it is excellent for insulation and for lowering a structure’s overall weight.
Conversely, aerated concrete is made in a different way and is also lightweight. Tiny gas bubbles are created during the mixing process when aluminum powder is added to the mixture and reacts with the lime and cement. The unique porous structure of aerated concrete, which is both strong and thermally efficient, is attributed to these bubbles.
Both materials are easy to work with and provide good thermal insulation, but depending on the application, one may be better suited than the other due to their distinct qualities. Examining the distinctions between aerated concrete and foam concrete will help you choose wisely for your upcoming construction project.
Manufacturing technology
The basic idea is the same: additives, sand, and cement are combined to guarantee foam formation. After that, the material solidifies in various settings and becomes usable. However, there are notable variations in the materials’ capabilities due to the peculiarities of the production process.
Foam concrete
What distinguishes aerated concrete from foam concrete? in copious amounts of inferior foam concrete.
With an electric drill in a barn, you can make it yourself. This is what some manufacturers do. The ingredients in this instance won’t be thoroughly combined. Small-batch, high-quality raw materials are expensive. Their decision to buy less expensive components comes from their desire to save money.
The following steps make up the proper procedure:
- The following are loaded into the mixer: clean water, high-strength Portland cement (from M400), sifted sand and foaming agent.
- The equipment can be located in the production shop or at the construction site.
- The components are thoroughly mixed.
- The mass goes into a foamed state, increases in volume and voids are formed in it.
- The finished mixture is unloaded from the mixer and can be used for its intended purpose.
Advice! Such simplicity of the technology leads to the fact that foam concrete is produced on adapted equipment from the cheapest raw materials. You should not buy a product in a dubious place in pursuit of a low price.
Application of foam concrete
Crucial! The distinction between foam concrete and aerated concrete is that the former enables product production without requiring the workpiece to be cut. The foam voids stay closed as a result, significantly lowering the material’s moisture permeability.
- The simplest method of using foam concrete is pouring monolithic structures, floor frames and self-leveling floors. In this case, a mobile unit is delivered to the site.
- For the production of foam blocks, the liquid mixture is poured into molds and allowed to harden. Each mold is designed for one block.
Fiber-reinforced foam concrete
The aerated concrete dough cannot have extra ingredients added to it due to the differences in production methods between aerated concrete and foam concrete materials. Fiber can be used to reinforce foam concrete.
Such an additive removes the possibility of the hardened mass cracking and greatly enhances the performance characteristics of blocks or monoliths.
The table shows that the bending strength can be increased three times by adding fiber. Because the building shrinks after construction, this indicator is crucial. At this point, the load is distributed in various directions, and the material may fracture.
The soil’s humidity is also altered by groundwater, precipitation, and freezing and thawing cycles. In these circumstances, there is a chance that the foundation will sag and the walls will move.
Aerated concrete
The material is produced using both autoclave and non-autoclave techniques. The first is only utilized in large businesses and calls for sophisticated equipment. The second process is comparable to making foam concrete. This technique can be used by small workshops, or they can create their own aerated concrete by hand.
Crucial! Chemical reactions lead to the foaming of aerated concrete. The process is broken by the presence of foreign materials. Because of this, only a small amount of reinforcing elements may be added to the mixture.
Components
Portland cement (any brand M400 and up), sand, negative lime, aluminum powder, and water are the main ingredients of aerated concrete. The final product’s required density and strength determine the proportions. Modifiers of different kinds can be added.
Non -circular aerated concrete
The simplest way to obtain the most affordable cellular concrete. Under natural circumstances, the substance foams and hardens.
There are actually three methods for doing this:
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At the facility, a solution is prepared in a conventional concrete mixer. The finished mass is poured into the formwork of a monolithic structure or molds for blocks. The molds can be bought (in the photo) or made by hand.
Crucial! It is not possible to evenly distribute the mass in a layer with this method without mechanical assistance, nor is it possible to calculate the precise amount of mixture needed for each mold. The material is leveled and the excess is moved to empty spaces as it foams. The blocks’ quality is greatly diminished by such actions, as they cause disruption to the natural process.
Take note! The sliced sides of the cavities open to let moisture in. It is imperative to enhance the waterproofing or utilize said blocks for interior wall applications. Cutting marks will be plainly apparent on the material upon closer inspection of the block.
- At factories, the initial blank has huge dimensions. A large amount of solution itself creates the conditions necessary for a chemical reaction.
It is easy to distinguish between foam concrete and aerated concrete when using the non-autoclaved method of analysis.
- Foaming and hardening of non-autoclaved aerated concrete occurs under natural conditions and is the result of a chemical reaction.
- Foam concrete foams mechanically, heavy particles of sand and cement are forced to rise in the solution.
These characteristics prevent foam concrete from producing high grades of aerated concrete strength. Reasonable application of non-autoclaved aerated concrete: filling interior masonry and monolithic partitions without supporting any weight.
Autoclaved
In this instance, higher pressure, temperature, and humidity are produced by placing the original dough inside an autoclave. In these circumstances, the foam encounters resistance and solidifies into a lattice. Consequently, a greater density can be attained.
It is evident that such aerated concrete cannot be used for monolithic construction when comparing the differences between foam concrete and aerated concrete made by the autoclave production method. However, the compressive strength of this aerated concrete is the best.
But the actual material of autoclaved aerated concrete is a crust that has solidified. Its ability to bend is essentially nonexistent. Aerated concrete producers and dealers never release data on this indicator or provide outrageous numbers.
The most common method for filling masonry walls in frame buildings is autoclaved aerated concrete. Only low-rise buildings use aerated concrete load-bearing structures.
Counseling! Some people believe that you can save money on the foundation because aerated concrete blocks are lightweight. You shouldn’t take advantage of this chance too seriously. The immobility of the structure should be guaranteed in full by the aerated concrete foundation supporting the load-bearing walls. The blocks might explode otherwise.
Aerated concrete and foam concrete with identical properties don’t cost all that much more or less. The delivery and caliber of the material have a major impact on the overall cost.
Technical characteristics
When comparing aerated concrete versus foam concrete, it is crucial to keep in mind that the latter’s greater capacity to absorb water is one of the key distinctions.
- When foam is formed, gas is released in aerated concrete. Paving their way to the exit, the molecules create voids that can be filled with moisture.
- In foam concrete, the mass is whipped mechanically, its "bubbles" are surrounded by a solution.
Crucial! An increased level of waterproofing is necessary when using aerated concrete.
Aerated concrete also has a higher compressive strength at the same time.
The difference between foam concrete and aerated concrete is easily discerned because the former is smooth, gray, and has few pores. Aerated concrete is nearly white and far lighter. It has numerous open pores and obvious cut marks on the sides.
The video in this article will provide additional information.
Both lightweight, adaptable building materials—foam concrete and aerated concrete—have different uses, characteristics, and manufacturing methods. In order to create a material with evenly distributed air bubbles, cement, sand, water, and a foaming agent are mixed together to create foam concrete. In contrast, aerated concrete is made by mixing aluminum powder into a concrete mixture, which triggers a chemical reaction that releases gas bubbles and creates a structure that is extremely porous. Even though both materials are very easy to work with and provide good insulation, builders can select the best material for a given construction project by being aware of their distinct qualities.
| Feature | Foam Concrete | Aerated Concrete |
| Composition | Made by adding foaming agents to concrete, creating small air bubbles. | Made by adding aluminum powder to concrete, causing a chemical reaction that forms tiny gas bubbles. |
| Density | Generally lower density, making it lighter. | Higher density compared to foam concrete, making it stronger. |
| Insulation | Better thermal and sound insulation due to its structure. | Good insulation but slightly less effective than foam concrete. |
| Strength | Lower compressive strength. | Higher compressive strength. |
| Cost | Usually cheaper due to simpler production process. | Typically more expensive because of the additional materials and processing. |
It’s critical to comprehend the distinctions between aerated concrete and foam concrete in order to make an informed choice. Both materials are common choices for construction because they are lightweight and offer good thermal insulation. They differ from one another, though, in a few key ways.
Foam concrete is renowned for being inexpensive and simple to produce. It is made by combining cement with a foaming agent, which makes the finished product lighter and more manageable. Its primary benefit is that it can be poured into nearly any shape, which makes it adaptable to a range of construction requirements.
However, the production process for aerated concrete, also referred to as autoclaved aerated concrete (AAC), is more intricate and calls for high-pressure steam curing. As a result, the product has improved structural integrity and is stronger and more consistent. Aerated concrete blocks are frequently chosen because of their accuracy and capacity to support weight.
The decision between foam concrete and aerated concrete ultimately comes down to the particular needs of your project. Foam concrete might be a better choice if cost and flexibility are your top priorities. Aerated concrete may be a better option if you require a material with greater strength and improved load-bearing capabilities. Before choosing between the two materials, carefully consider your needs as each has special advantages.
