What is cellular concrete?
Cellular concrete is a flowable and lightweight concrete that contains foam from a foaming agent evenly mixed into the concrete. The introduction of micro-bubbles into the concrete matrix provides the final product with unique properties, incl. low structural load, high thermal insulation, very good sound absorption, minimal water absorption and excellent fire safety.
AirForm - excellent cellular concrete technology
Ultra light concrete with low density from 150 -600 kg m3 means reduced load on load-bearing structures.
Effective thermal insulation material because it contains air cells. They significantly reduce energy consumption due to the low thermal conductivity (λ). The coefficient of thermal conductivity (λ) varies from 0.050 to 0.19 W / mK depending on the density.
Great sound absorption properties due to the micro-air cells in its structure.
Mineral - it is completely fireproof, the material has A1 fire safety class.
Environmentally friendly sustainable material and fully recyclable.
It does not emit harmful chemical fumes, its PH level reduces the risk of mold and improves air quality in the room.
It is not inhabited by rodents and insects.
Quick to produce and easy to install, right on site. Saving construction time and money.
High frost resistance, the material withstands freezing and thawing very well.
The material has perfect fluidity, completely fills all gaps and encapsulates all communications that are embedded in the material.
It has good load distribution properties without creating significant lateral pressure.
Does not change its physical and technical properties for more than 100 years.
Installation costs are lower because this material is no longer required to be transported, stored or treated (eg cut).
Efficient heat, sound and fire insulation technology that improves the energy efficiency of buildings from wall to wall and from floor to ceiling .
In construction used in floors, roof terraces, attics, mezzanines, structural blocks, and many other places.
In road construction, it is used at the bases of roadways and sidewalks, at the bridge abutments and behind retaining walls to create zero or low loads on the soil.
Geotechnical solutions include fast and economical filling of cracks in the soil, abandoned pipelines, tanks, etc., eliminating the risk of backfill loading.
Modern equipment and innovative additives allow to produce high-strength cellular concrete on site and to ensure constant and stable product quality from the first to the last m3.
AIRFORM APPLICATIONS
Cellular concrete has many uses and does not have one singular advantage. Depending on the application, it may be chosen for its thermal and acoustical insulative properties, pumpability and flowability, ease of handling due to its light weight, or as a cost saving alternative to fill materials. Throughout the world, cellular concrete is used in building and construction applications such as roof decks and floor decks, and geotechnical applications such as annular space filling in slip lining and void fill abandonment. Cellular concrete can also be found in architectural and precast applications. Below are many of the more common applications for cellular concrete; however, it’s not an exhaustive list.
Void Filling: Sinkholes, wells, tunnels, cisterns, abandoned utility pipes, annular grouting. Flows easily and provides reduced weight on soil.
Soil Remediation: When poor subsoil conditions exist, cellular concrete can be used to create a strong base while reducing burden on subsoils.
Utility Trench Fill: Protects and supports utility lines and reduces or eliminates need for compaction.
Culvert Trench Fill: Prevents later soil settlement and subsequent dips in road.
Bridge/Overpass Abutment Fill: Eliminates post-construction settling. Because cellular concrete does not need compaction, it won’t compress over time, creating a “dip” in a bridge or overpass approach. Additionally, lateral loads against the existing abutment are essentially eliminated.
Retaining Wall Backfill: The lateral load reduction is the primary advantage. Cellular concrete can also greatly reduce potential damage to the geogrid during the backfill process.
Fence Panels Along Highways: For sound control and visual blocking. Cost savings potential due to weight savings.
Crash Barriers/Energy Absorption: Pre-cast variable density cubes or pour on location.
Floor Decks: Reduces structural weight while maintaining quality of concrete floor. Used for leveling and replacement of gypsum-based mixes.
Roof Decks: Reduces weight and provides thermal and sound insulation. Moderate slopes are possible.
Precast Specialties: Reduces weight and cost. Reduces transport costs/allows more pieces per truckload. Easier installation.
Thermal Backfill and Sub-slab Fill: Provides thermal insulation and water resistance, and reduces hydrostatic lateral load on foundation.
Interior Walls: Cast on site tilt-up or panel assemblies. Reduces weight and cost below full density concrete wall. More soundproof and fire resistant than stud wall.
Retaining Wall Base: Proper mix design will be self-leveling and can greatly speed base construction and improve load capacity.
Sidewalks, Patios, and Porch Decks: Reduces weight and cost.
Carved Concrete Sculptures: Cellular concrete in the 400-600 kg/m3 range can be carved and shaped with chain saws, hand tools, and other methods to create artwork from a unique medium.
AirForm Density
AIRFORM density can be tailored to your needs and requirements to provide the best compromise between insulation performance and structural strength.
AIRFORM can be produced in the density range from 150 to 600 Kg/m3.
Floors on the ground
For floors on the ground, AIRFORM replaces traditional multi-layer systems, which most often consist of compacted sand, compacted rubble, expanded polystyrene, waterproofing film, concrete, with one monolithic layer .
Pipeline Damage
AIRFORM allows quick repair of leachate damage caused by pipeline damage or rain.
Road Construction
AIRFORM is excellent for soil reinforcement and road construction. Low weight and fine cellular structure allows to absorb kinetic energy during compression or deposition of the upper structure. Cellular concrete has been used in highway construction in the United Kingdom since the 1970s.
Fully Recyclable
AIRFORM is the insulation material of the future. It has a lower CO2 footprint compared to other insulation methods due to several factors: its high air content, its high durability (over 100 years) and its ease of handling and complete recyclability. The combination of these factors also significantly reduces the costs of reconstruction or renovation, as well as the impact on the environment.
Production on site
SKYSTONE mobile plant can produce AIRFORM material in the amount of 4m3 to 30m3 per hour, on site and move up to 600m horizontally and 50m vertically with pumps.
FREQUENTLY ASKED QUESTIONS
What is cellular concrete?
Cellular concrete is special - light, low density concrete.
Cellular concrete is made of Portland cement, water and specially prepared foam. This foam looks like a shaving cream and its amount is varied to control the density of the cellular concrete according to the requirements of each specific project.
When a controlled amount of synthetic or protein-based foam is introduced into the concrete mortar, it encapsulates billions of micro-bubbles of the air by mechanical and chemical reaction with the concrete mortar components, resulting in lightweight concrete with a density, that can be as little as 100 kg/m3. Cellular concrete can be so light because the cement particles cover the small air bubbles, making them stable enough to withstand the hydration process, leaving behind an even air void matrix.
What are the properties of cellular concrete?
Controlled and stable introduction of micro-air bubbles into the concrete matrix gives the final product unique properties. The main ones are:
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low mass, which translates into low structural load
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high thermal insulation
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great sound absorption
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minimal water absorption
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excellent fire safety
No less important is that cellular concrete has:
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ideal fluidity, it completely fills all gaps and encapsulates all communications that are embedded in the material, it is self-compacting and self-leveling
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it is an easy-to-handle, excavable, fully recyclable, sustainable and environmentally friendly material
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it has high freeze-thaw resistance
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it does not emit any harmful chemical fumes at all
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it is not inhabited by rodents and insects
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over time, its physical and technical properties only improve
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installation costs are lower because the transportation of the product is eliminated - SKYSTONE mobile plant can produce AIRFORM material in the amount of 4m3 to 30m3 per hour, on site and move up to 600m horizontally and 50m vertically with pumps.
The combination of all these factors is essential, because AirForm:
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reduces the cost of any new construction, alteration or refurbishment project,
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reduces the time required to implement the project, as well as minimizes the impact on the environment.
What is the workability (plasticity) class of cellular concrete?
The workability class of cellular concrete is S5. Cellular concrete flows easily and spreads through the formwork without compaction. Therefore, it can also be used in tightly reinforced constructions and in hard-to-reach places.
What is the frost resistance of cellular concrete?
Since the largest component of cellular concrete is air, AirForm has a very high frost resistance. Its exact measure depends on the density of the acellular concrete produced. For example - for cellular concrete with a density of 400-600 kg/m3 the frost resistance index is F300. This means that such concrete can withstand at least 300 freezing cycles, after which it will not lose more than 5% of its strength.
Where is cellular concrete used?
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Cellular concrete is used in the construction of floors on the ground, above mezzanine floors, roof terraces, attics, filling of walls and structural blocks, and many other places.
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In road construction, it is used at the bases of roadways and sidewalks, at the bridge abutments and behind retaining walls to create zero-additional or low loads on the soil.
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Geotechnical solutions include fast and economical filling of cracks, abandoned pipelines, shafts, leachate, eliminating the risk of increased load on the soil.
How much does cellular concrete cost?
The cost depends on many factors, including, but not limited to: the required density of cellular concrete, the size of the project, the location, the site conditions, and many others.
The cost of cellular concrete, like the cost of any material, should not be compared with the cost of other materials as EUR/m3 versus EUR/m3, as it ignores a number of factors affecting the total cost of the project.
When evaluating the costs, the delivery costs of each specific material, the size of the space required for placing the material and performing the work, the time required for its installation, the amount of labor and costs, as well as the degree of technological complexity of the material installation must be taken into account.
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AirForm installation has minimal delivery costs as it is produced on site.
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AirForm does not require material storage, as it is produced at the time of installation.
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AirForm is quick to apply because it is easy to flow, encapsulate, self-leveling and self-sealing.
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SKYSTONE mobile plant can produce cellular concrete in the amount of 4m3 to 30m3 per hour.
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AirForm is installed by a knowledgeable SKYSTONE team and you do not have to use your staff.
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The SKYSTONE cellular concrete production plant occupies an area of only 9 m2 and, if necessary, it can be placed at a considerable distance from the site, as cellular concrete can be pumped through pipes up to 600m horizontally and 50 m vertically.
When comparing the cost of cellular concrete with other aggregate materials and methods, the greatest savings are often observed in production and delivery costs, labor costs and the timing of the project. SKYSTONE project managers are available to help determine the numbers and prices for your specific project budget.
Can cellular concrete be cut or excavated?
Cellular concrete is a low-density material that can be easily cut with hand or motorised saw and excavated using mechanical equipment such as excavator.
Is cellular concrete waterproof?
No, it is not, but its moisture absorption capacity is low. In direct contact with water (immersed), aerated concrete, although very slowly, still absorbs moisture, but when direct contact disappears, it dries quickly. Low absorbency is ensured by the closed air pore structure of aerated concrete. Over a very long period of time, completely submerged in water and without contact with air, aerated concrete will absorb moisture up to ~ 50% of its bulk. Its moisture absorption capacity is inversely proportional to the volumetric mass of the manufactured cellular concrete - the higher the volumetric mass, the lower the absorption capacity. It is easy to protect cellular concrete from direct and long-term contact with moisture - by laying a moisture-proof membrane (for example, polyethylene film) before its installation.
Can I place the equipment directly on the cellular concrete?
To prevent damage to the surface of the material, it is recommended to install a protective material over the cellular concrete (it can be something as simple as plywood).
How is cellular concrete installed and how far can the material be pumped?
Cellular concrete is poured in the required place, using 4 ”concrete hoses in the required volume. Cellular concrete can be pumped through hoses up to 600m horizontally and 50m vertically. Please contact us to discuss your project needs.
How long do I have to wait to apply the next layer of cellular concrete or to be able to walk on the material?
Cellular concrete usually is hard enough to walk on in about 48 hours. After 2 days you will be able to pour the next round (if the project so provides) as well as walk on the material to continue your project.