CELLOLITE BLOCKS

Mambakkam, Chennai, Tamil Nadu

Foam concrete, also known as Lightweight Cellular Concrete (LCC), Low Density Cellular Concrete (LDCC), and other terms is defined as a cement-based slurry, with a minimum of 20% (per volume) foam entrained into the plastic mortar. As mostly no coarse aggregate is used for production of foam concrete the correct term would be called mortar instead of concrete; it may be called foamed cement as well. The density of foam concrete usually varies from 400kg/m³ to 1600kg/m³. The density is normally controlled by substituting fully or part of the fine aggregate with foam.

Manufacturing

Foamed concrete typically consists of a slurry of cement or fly ash and sand and water, although some suppliers recommend pure cement and water with the foaming agent for very lightweight mixes This slurry is further mixed with a synthetic aerated foam in a concrete mixing plant. The foam is created using a foaming agent, mixed with water and air from a generator. The foaming agent must be able to produce air bubbles with a high level of stability, resistant to the physical and chemical processes of mixing, placing and hardening.

Foamed concrete mixture may be poured or pumped into moulds, or directly into structural elements. The foam enables the slurry to flow freely due to the thixotropic behavior of the foam bubbles, allowing it to be easily poured into the chosen form or mould. The viscous material requires up to 24 hours to solidify or as little as two hours if steam cured with temperatures up to 70C to accelerate the process. depending on variables including ambient temperature and humidity. Once solidified, the formed product may be released from its mold. A new application in foam concrete manufacturing is to cut large concrete cakes into blocks of different sizes by a cutting machine using special steel wires. The cutting action takes place before the concrete has fully cured.

Applications

Foamed concrete can be produced with dry densities of 400 to 1600kg/m³ (25 lb/ft³ to 100 lb/ft³), with 7-day strengths of approximately 1 to 10 N/mm² (145 to 1450 psi) respectively. Foam concrete is fire resistant, and its thermal and acoustical insulation properties make it ideal for a wide range of purposes, from insulating floors and roofs, to void filling. It is also particularly useful for trench reinstatement.

A few of the applications of foam concrete are:

• bridge approaches / embankments
• pipeline abandonment / annular fill
• trench backfill
• precast blocks
• precast wall elements / panels
• cast-in-situ / cast-in-place walls
• insulating compensation laying
• insulation floor screeds
• insulation roof screeds
• sunken portion filling
• trench reinstatement
• sub-base in highways
• filling of hollow blocks
• prefabricated insulation boards

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