What is foam concrete and where is it used?

Foam concrete is a multipurpose construction material that is made of foam, cement, and water. It is strong and lightweight at the same time. The particular lightness and insulating qualities of foam concrete are a result of the porous structure created by this special mixture. Foam concrete works well for a variety of construction projects because it is simpler to work with and can be pumped or poured into place, unlike traditional concrete.

The thermal insulation of foam concrete is one of its key benefits. It can save energy in buildings because of its high air content, which contributes to temperature stability. Furthermore, foam concrete has a high fire resistance, which gives buildings an additional degree of security.

Applications for foam concrete are numerous. It is frequently used in precast elements, panels, and building blocks, where its insulating qualities and low weight are especially useful. It can also be used as a sub-base for roads and pavements, as well as for trench reinstatement and void filling. Its adaptability makes it suitable for infrastructure projects as well as residential and commercial building.

In conclusion, foam concrete is a useful material in the construction industry because of its combination of light weight, thermal insulation, and fire resistance. Because of its versatility and ease of use, it will always be a crucial part of many engineering and construction applications.

What is Foam Concrete?	Where is Foam Concrete Used?
Foam concrete is a type of lightweight concrete made by mixing cement, sand, water, and foam. The foam creates air bubbles, making the concrete lighter and more insulating.	Foam concrete is used in a variety of applications including insulating roofs, filling voids, creating sound barriers, and making lightweight blocks for construction. It is also used for leveling floors and as a base for roads and foundations.

What are the features of foam concrete

After hardening and gaining operational strength, porous concrete made by adding foaming ingredients to a pre-mixed cement-sand mortar develops a distinctive structure.

The substance has several qualities, including:

• non-uniform distribution of air cells in the foam concrete mass. Uneven placement of pores slightly reduces strength;
• stable cavity size not exceeding 0.4–0.5 cm. The constancy of sizes is achieved by thoroughly mixing the foaming agent;
• pore concentration not exceeding 75% of the volume of the foam concrete mass. Due to the cellular structure, the specific gravity is reduced;
• closed form of air cavities. Sealed cells increase the resistance of foam concrete products to moisture absorption.

The building material’s vapor permeability and thermal insulation qualities are improved by the presence of internal cells.

Foam blocks – what is it?

Foam concrete composite products are in high demand in the private housing construction industry. The majority of developers are familiar with a common building material and know what a foam block is. For those who are unaware, foam concrete blocks are the end result of the material hardening in molding containers containing foamed cement mortar. Different kinds of blocks are classified into types based on their unique attributes. The internal dimensions of the casting molds match the sizes of the foam blocks.

Foam blocks can be easily identified by their features:

• shape of the product – a rectangular parallelepiped;
• increased roughness of the outer surface;
• gray color of the building material (this is due to the use of cement).

Furthermore, a piece of foam block submerged in water can be used to confirm the material’s ability to float on the water’s surface.

How foam concrete blocks are classified

The following are impacted by the amount of internal cavities in foam concrete blocks:

• specific gravity of the product;
• the magnitude of the perceived load;
• the scope of application of foam concrete.

Depending on the material’s density, the classification allows for the following division of foam concrete into varieties:

• thermal insulation foam blocks. They are marked with the alphanumeric designation D150-D400. The number in the marking indicates the mass of one cubic meter of foam concrete, indicated in kilograms. According to strength characteristics, the material is classified B0.75. Foam concrete of this class is capable of withstanding a load per square centimeter of area equal to 9 kg. At the same time, the integrity of the massif is maintained and cracks do not form;
• heat-insulating structural concrete blocks. Compared to heat-insulating blocks, they have increased density and improved strength properties. Marked with the designations D500, D600, D700 and D800. The maximum density of structural heat-insulating blocks is 0.8 t/m3. The maximum permissible force at which the structure of foam concrete blocks is not damaged is up to 30 kg/cm2;

• structural products. These include foam concrete materials marked with the designation D1000, D1100 and D1200. The main distinguishing feature of structural foam blocks is their increased density. The weight of one cubic meter of structural foam concrete reaches 1200 kg, which allows the material to maintain its integrity under significant loads. The maximum strength class of foam blocks is B12.5.

The higher concentration of internal cavities enhances the foam concrete’s ability to insulate against heat and also helps to improve the room’s sound insulation. Stronger foam concrete used to build load-bearing building walls has fewer air pores because the strength properties of the material are inversely proportional to the volume fraction of internal cells.

Composites made of foam concrete are used in different phases of home building. The features of the block application are influenced by the properties of the material. Block foundation construction is not possible due to the cellular structure of the foam concrete massif. Several kinds of foam concrete are used to build internal partitions, walls, and ceilings in addition to providing thermal insulation.

The following uses are made of the structural building material:

• construction of building boxes that bear the loads from the weight of the building and roofing structure;
• construction of internal walls related to low-load parts of the building;
• construction of interior partitions that do not bear vertically directed forces.

The following areas of the building are intended to be insulated by thermal insulation blocks:

• interfloor ceilings made of reinforced concrete;
• load-bearing walls of the building box in contact with cold air;
• under-roof space, which is a source of heat loss.

Because of their unique properties, thermal insulating foam blocks can be used in technology to provide thermal insulation for pipes, equipment, and devices that are heated to temperatures between 450 and 550 °C.

Building facades and load-bearing walls can be insulated using thermal insulation and structural foam blocks, which combine the benefits of structural and thermal insulation materials. The thermal insulation properties of foam block houses are higher than those of brick buildings. Installing blocks with the same profile ensures strength and minimizes heat loss through the wall’s surface.

Cellular concrete, another name for foam concrete, is a lightweight, adaptable building material that is created by incorporating foam into a cement mixture. As a result, the porous structure is made of less material than conventional concrete. It is frequently utilized in construction projects for a number of purposes, such as lightweight fill, soundproofing, and insulation. Foam concrete is a popular option for both residential and commercial building projects because of its affordability, ease of use, and environmental advantages.

What is foam concrete made from?

The following materials are utilized in the production of foam concrete:

• Portland cement marked M400, which is a binder. The use of higher grade cement has a positive effect on the properties of foam concrete;
• river sand used as a filler. Replacing river sand with expanded clay granules improves thermal insulation properties and strength;

• foaming ingredients. Used in the form of a concentrate prepared on the basis of bone glue, rosin, gelatin or protein-containing components;
• warm water. The optimum water temperature, according to the requirements of the technological process, is 22–25 °C, and the recommended ratio with cement is 1:2.5.

By adhering to the technology’s prescribed composition and utilizing premium raw materials, foam concrete can be produced with the necessary performance characteristics.

Specifics of foam concrete production

Foam concrete is made using a variety of techniques:

• classical technology. It regulates the need to use a foam generator that supplies foaming agent through pipes into the prepared cement-sand composition. The working solution, mixed in a mixer with a foaming agent, is poured into molding containers or fed through pipes to the work site. During the cement hydration process, the foam material hardens, forming a porous structure inside the massif. Hardness is gained under natural temperature conditions corresponding to the state of the environment;
• porization method. The name of the manufacturing method is associated with the use of a special unit – a porizer. It ensures the introduction of dry components into the foaming agent stream. Particles of the cement-sand mixture are deposited on the shell of foam bubbles. As a result, a working foam material is formed, fed through pressure mains to the work site. Professional builders call the porization method of manufacturing foam concrete the dry mineralization method. It is in demand in the field of industrial construction for the constant supply of foam concrete mixture.

Examine the advantages of each manufacturing process and run cost analyses before selecting a method for making foam concrete.

Advantages of foam concrete

Let’s talk about the benefits of foam blocks. The principal benefits of foam concrete are:

• increased thermal insulation properties. The material allows you to maintain a comfortable room temperature and is more than 2 times superior to brick in this indicator;
• reduced density of foam blocks. Due to its light weight, it is easier to transport the material, it speeds up the implementation of wall laying activities, and it eliminates the need to build a powerful foundation;

• the possibility of using foam blocks for the construction of load-bearing walls.

The following qualities of foam concrete enable structures up to nine meters high to be constructed with the material:

• resistance to the effects of low temperatures. Foam blocks do not collapse under temperature changes and retain their structure as a result of deep freezing with accelerated thawing;
• resistance to open flame and high temperature. Properly manufactured foam concrete does not collapse in extreme situations;
• environmentally friendly material. Use of environmentally friendly raw materials for the production of foam concrete eliminates the release of harmful substances during operation;
• possibility of manufacturing foam concrete products by small enterprises or directly at the construction site. Simplicity of the technology allows to reduce the estimated cost of construction;

• long period of use. Foam concrete retains its structure and performance characteristics regardless of the duration of operation;
• easy mechanical processing of foam blocks. Using hand-held power tools allows you to easily make grooves and holes in the foam concrete massif or cut the block into pieces.

Now that you are acquainted with the material’s advantages, focus on its disadvantages.

Disadvantages of foam concrete products

Now let’s investigate the drawbacks of foam blocks. Principal drawbacks:

• increased shrinkage of the foam concrete mass;
• the need to protect foam concrete from moisture absorption;
• insufficiently high strength properties;
• susceptibility to impact and increased loads;
• difficulty in using standard fasteners for porous materials.

Foam concrete needs to be stored in a warehouse and handled carefully while being transported. We can determine whether foam blocks are appropriate for completing the tasks after weighing their benefits and drawbacks.

Recommendations for choosing foam concrete products

Experts advise being aware of the following points:

• image of the manufacturer;
• no defects on the surface;
• correct block geometry.

When purchasing foam concrete blocks, make sure the block’s specifications match the guidelines listed in the quality certificates. You should also take note of the manufacturing date. No sooner than one month following production can foam concrete be put to use.

Known for its insulating qualities and low weight, foam concrete is a versatile building material. It is made by combining a foaming agent with cement to produce a frothy, airy texture that solidifies into a lightweight but durable material. It’s a great option for a variety of construction applications because of its distinctive composition.

Foam concrete is primarily used for wall, roof, and floor insulation. Because of its capacity to hold heat, buildings become more energy-efficient and require less energy. Furthermore, foam concrete is frequently used for void filling because it can flow easily and without adding a lot of weight into spaces that need to be filled.

Foam concrete is used for roadbeds and foundations in infrastructure projects. Because of its light weight, underlying soils are not as burdened, potentially preventing settlement problems. Because it can be molded into a variety of shapes and forms, it is also used to create ramps and slopes.

Foam concrete is generally advantageous due to its ease of application and favorable environmental effects. Because of its exceptional insulating qualities and lightweight design, it is a highly valued material in contemporary building that offers both practical and financial advantages. Foam concrete is expected to be used even more often as construction technology develops, supporting more economical and environmentally friendly building techniques.

Video on the topic

Foam block. Foam concrete. What is it?

What is foam concrete made of?

Why we don"t praise foam concrete

Foam concrete