We reduce the load on the foundation – we make the floor from expanded clay concrete

Any construction project must start with the construction of a solid and long-lasting foundation. However, especially for large structures, the load on the foundation can pose a serious risk. One practical solution to this problem is flooring made of expanded clay concrete. This novel material is a great option for contemporary construction because it not only lessens the load on the foundation but also provides a number of additional advantages.

Made by heating clay to a high temperature, expanded clay balls are incorporated into expanded clay concrete, which is a lightweight aggregate concrete. Expanded clay concrete is made by combining a porous, lightweight aggregate produced by this process with cement and water. As a result, a material that is robust and long-lasting but much lighter than conventional concrete is created.

The lighter weight of expanded clay concrete makes it a great choice for flooring. This material can help you drastically reduce the load on the foundation, which can be especially helpful for projects where the foundation’s capacity is a constraint. In addition to improving overall structure safety and stability, this may result in financial savings during the design and construction of the foundation.

Expanded clay concrete has good thermal insulation and sound absorption in addition to being lightweight. For floors in homes, offices, and other locations where comfort and noise abatement are crucial, this makes it the perfect option. Furthermore, the porous nature of the material increases its resistance to moisture and fire, extending the building’s overall lifespan.

All things considered, expanded clay concrete offers many additional advantages and is a flexible and effective way to lessen the load on foundations. Due to its special qualities, it is a valued building material in contemporary architecture, contributing to the creation of comfortable, energy-efficient, and strong structures.

Benefit	Description
Lightweight	Expanded clay concrete is lighter than traditional concrete, reducing the load on the foundation.
Insulation	It provides better thermal and sound insulation, making homes more energy-efficient and quieter.
Cost-effective	Using expanded clay concrete can lower construction costs due to its reduced weight and insulating properties.
Durable	This material is durable and resistant to moisture and temperature changes, ensuring long-lasting floors.

Basic requirements for floors

When making your choice, take into account:

• The material from which the external and internal load-bearing walls will be made.
• The size of the spans between the walls on which the slabs rest.
• Estimated load on the floor.

They need to meet the following requirements:

• Required design load-bearing capacity;
• Sufficient rigidity with minimal permissible deflection;
• High degree of resistance to fire;
• Good sound insulation;
• Low thermal conductivity.

The weight of all equipment that will be placed on it, including heating boilers, furniture, plumbing fixtures, and other heavy objects, is taken into consideration when calculating loads.

Using expanded clay concrete for your floors is one practical way to reduce the load on your foundation, which is necessary for long-term structural integrity. This lightweight material provides superior durability and insulation while also reducing stress on the foundation. Expanded clay concrete is a wise choice for both new construction and renovations since it guarantees a stable and energy-efficient building.

Advantages and disadvantages of expanded clay concrete floors

Expanded clay concrete floors are widely used, which suggests that these kinds of structures have many benefits.

Let’s focus on the principal ones:

In the field of construction, similar products made of lightweight concrete are an inventive solution. By decreasing its own weight, the building’s foundation is subjected to less strain on the supporting structures.

• Sufficient strength of expanded clay concrete makes it possible to use materials from it in the construction of ceilings.
• Increased soundproofing and heat-insulating parameters allow to do without additional floor insulation and noise insulation.
• If expanded clay blocks or slabs are used as a floor, their smooth and even surface reduces the cost of installing floors.
• Since the production of expanded clay concrete materials is not expensive, their cost is relatively small.

When compared to materials composed of heavy concrete, the products in question have a lower strength, which is their main but relative disadvantage.

Types of expanded clay concrete floors

These products are supported by columns or wall structures in buildings.

They fall into the following categories based on the technology of the device:

• Prefabricated systems;
• Monolithic;
• Prefabricated-monolithic types.

Prefabricated ones are put together using components that are produced industrially, while monolithic ones are made right there on the construction site. Using precast components and single sections together is known as the precast-monolithic option.

Precast floors made of expanded clay concrete slabs

Precast products shorten building construction times dramatically. It is necessary to use heavy construction equipment simultaneously. Compared to the cost of installing a monolithic structure, the total cost of delivery to the site will be significantly higher.

When there are no appreciable dynamic loads, the slab mentioned above is employed.

Three categories of material exist:

Concrete with expanded clay is poured into a steel reinforcement frame to create a monolithic solid. They are very strong, but they weigh a lot too. GOST 12767-2016 standardizes production.

These categories vary in the following areas:

• Thickness;
• Scheme of support on load-bearing structures in the building.

The structural expanded clay concrete used in the hollow version has a minimum density of 1500 kg/m3 and is medium density.

Oval, pear, or round voids are used to create hollow-core structures. As a result, compared to the solid version, they are lighter and have better sound and heat insulation. GOST 9561-2016 standardizes manufacturing.

There are four thicknesses for slabs: 0.16 m, 0.22 m, 0.26 m, and 0.3 m. The material’s average density shouldn’t be higher than 1400 kg/m3.

The slab with longitudinal and occasionally transverse stiffeners is called the ribbed type. They are able to bear heavy loads because of this. produced in compliance with GOST 21506-2013.

The dimensions of manufactured ribbed products are 5.65 m for length, 0.935 m for width, 1.485 m for length, and 2.985 m for thickness of slabs. Expanded clay concrete with a medium density ranging from 1600 kg/m3 to 2000 kg/m3 is used in their production.

Crucial! Only after the masonry mortar in the walls has strengthened enough can installation start.

If the blocks are solid, laying is done the same way as on brick walls. In order to prevent slab skewing, the top of the masonry must be leveled prior to installation work. The product is then mounted on a layer of cement-sand mortar that has been applied. The wall support needs to be installed at least 16 centimeters deep.

When building wall structures out of hollow blocks, the walls’ perimeters must be strengthened before they are installed. The reinforced belt is made up of a concrete mortar-filled steel reinforcement frame.

U-shaped expanded clay concrete blocks are another option; they are made especially for projects like this. Once the reinforcement is inside the block, mortar is used to concrete it.

Monolithic expanded clay concrete floors

Creating a monolithic floor with your hands is a feasible task. It will be substantially less expensive than a prefabricated building. Concurrently, there is a notable rise in the duration of construction and labor expenses associated with its installation.

The gadget is made of the following materials:

• Steel profiles;
• Galvanized profiled sheeting;
• Expanded clay concrete slab.

Steel I-beams or channels fill the function of load-bearing beams in steel-reinforced concrete coverings. Permanent formwork and external working reinforcement are provided by galvanized profiled sheeting.

STO 0047-2005 states that there are numerous benefits to this kind of device compared to a traditional reinforced concrete structure that uses rod reinforcement:

• Steel consumption for beams is reduced by 15%.
• Labor costs for production work are reduced – from 25% to 40%, construction time – up to 25%.
• Weight is reduced – from 30% to 50%.
• Construction height is reduced by 10%.
• Overall rigidity is increased.
• It is possible to place all communications inside the corrugated sheeting.

The following requirements must be met in order to use steel-reinforced concrete:

• Operation in a non-aggressive or slightly aggressive environment;
• Humidity conditions up to 75%;
• Temperature conditions up to +30 degrees;
• Use of concrete mixtures without chlorides;
• Fire resistance limit RE

The coating is installed using materials that meet the following specifications:

• Expanded clay concrete must have a class of at least B12.5;
• Profile sheeting made of rolled steel rolled using the cold method, the yield strength of which is from 230 N/mm2 to 360 N/mm2, tensile strength from 300 N/mm2 to 460 N/mm2, relative elongation from 16% to 22%;
• Regular profile of reinforcement class A-3, and wire reinforcement class Bp;
• Rolled or composite steel beam profiles.

Special anchors or ribs applied during rolling are needed to achieve corrugated sheets’ reliable adherence to expanded clay concrete.

• If it is not planned to make a concrete floor screed in the future, then the minimum thickness of expanded clay concrete above the edge of the corrugated sheet should be 5 cm. In case of a coupler – at least 3 cm.
• Profiled sheets are fastened together with an overlap along the longitudinal edges using rivets or self-tapping screws with a pitch of no more than 50 cm. The flooring is attached to the beams with self-tapping screws or dowels.
• On the extreme supports, this is done in each corrugation, on the intermediate ones – through one corrugation. The flooring support on the extreme supports should be at least 4 cm, on the intermediate ones – 6 cm.
• If the design provides for the use of reinforcement above the support, then it is necessary to be guided by SNiP 2.03.01-84. If it is not available, a reinforcing mesh of class Bp-I wire with a diameter of at least 3 mm and a cell size of 2 cm x 2 cm is used.
• To create technological openings, formwork is made in the slab along the perimeter of the opening. Additional reinforcement is installed around the structure in order to strengthen it.

The profiled sheeting that is used needs to have a minimum thickness of 0.7 mm.

You must be able to properly prepare the concrete solution in order to manufacture the product on your own. This picture will be useful for that.

Additionally, building an interfloor ceiling in a private home can be facilitated by following the instructions provided in the article’s video.

It makes sense to use expanded clay concrete for flooring in order to lighten the strain on your foundation. Because it is robust and lightweight, this material is perfect for use in both residential and commercial structures. You may be able to reduce construction costs and ensure a more sturdy and long-lasting structure by choosing expanded clay concrete.

In addition to its strength and low weight, expanded clay concrete has great insulating qualities. This implies that it may contribute to the maintenance of cozy interior temperatures, which may ultimately result in energy savings. Its strong sound insulation further makes it a sensible option for busy urban settings or multi-story buildings.

The fire and moisture resistance of expanded clay concrete is an additional advantage. These qualities give builders and homeowners alike peace of mind by extending the life and safety of your structure. Costs associated with maintenance and repairs can be greatly decreased when there is less chance of fire or water damage.

Including expanded clay concrete in your flooring designs is a sustainable choice in addition to a technical one. This material supports environmentally friendly building techniques by frequently utilizing recycled materials. Selecting expanded clay concrete is a move in the direction of a more environmentally friendly building industry.

All things considered, expanded clay concrete has many advantages that make it a better option for flooring. It offers durability and safety, reduces the load on foundations, and offers superior insulation. With these benefits in mind, it’s understandable why more builders are using expanded clay concrete for flooring applications. It’s a prudent investment for any size construction project.

Video on the topic

Completion of work on a floor slab made of expanded clay concrete

Interfloor ceiling with a lightweight reinforced concrete slab made of expanded clay concrete. Mezzanine floor for an office.

Foundation for a house made of expanded clay concrete blocks

Foundation for a house made of expanded clay concrete blocks

February 17, 2025 Collection of loads on foundations. Part 1

Foundation made of expanded clay concrete blocks