Production of Foamed Concrete

The production of foamed concrete on a small scale is a fairly easy process which does not involve any expensive or heavy machinery  and in most cases uses equipment that is already available for normal concrete/mortar production.

Depending on the volume of concrete required (normally limited to less than 20 cubic meters/day) one will only need ;

Equipment

1. Normal concrete/mortar mixer or special mixers for foam concrete.

2. Foam Generator

3. Formwork (if producing pre- cast components)

Materials

1. Fine sand 

2. Cement

3. Water

4. Stable foam

Simple Mix Design

The first step is of course to decide the wet density and how much foamed concrete you require.

The raw materials required would be ;

cement = 200 kg

sand = 200 kg (assuming dry sand)

water = 100 kg (including water in foam)

then from the target volume of  foamed concrete (0.5m3) calculate the air content and final foam volume in the mix.

If foam output from Portafoam = 1.5 lit/sec then one would need to pump generator for 250/1.5 = 2.77 min. The practical way would be to pump for 166 sec and add the rest of  the foam using a measured container. 

Mixing procedures

Now that you have worked out the amount of  materials required to make the foam concrete add them dry first starting with the sand and cement. Mix dry constituents for a few minutes and add water in stages and make sure the mixing is thorough. Then add foam to the wet slurry and ensure foam has been completely mixed with the mortar.

After mixing is completed check that the wet density of  the foamed concrete  is close to what is required. The dry density (oven dried) of foamed concrete is normally less than its wet density, depending on w/c ratio, density and also on the cellular structure obtained. So do not forget to target a value of wet density much higher than what we actually require (dry).

ADVANTAGES OF FOAMED PORTAFOAM BLOCKS

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