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aercel SP20

The document discusses the evolution of lightweight cellular concrete admixtures, particularly focusing on the use of foaming agents to reduce the weight of cementitious mortars for improved waterproofing applications. It outlines the historical context, various methods for weight reduction, and the essential requirements for foaming agents and production plants to ensure effective and consistent results. The document emphasizes the need for a reliable system capable of producing foamed concrete with desirable physical properties while addressing market demands.

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Walid Hozayen
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20 views4 pages

aercel SP20

The document discusses the evolution of lightweight cellular concrete admixtures, particularly focusing on the use of foaming agents to reduce the weight of cementitious mortars for improved waterproofing applications. It outlines the historical context, various methods for weight reduction, and the essential requirements for foaming agents and production plants to ensure effective and consistent results. The document emphasizes the need for a reliable system capable of producing foamed concrete with desirable physical properties while addressing market demands.

Uploaded by

Walid Hozayen
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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AERCEL SP20

Edition: May 2009


Version: 9051
CELLULAR CONCRETE ADMIXTURE
Division: O3 SYNTHETIC BASE FORMULA
Section: # 3050

BACKGROUND

For centuries waterproofing materials have been known to provide prolonged effective-
ness only when applied over properly sloped surfaces; the key: to ensure prompt evacu-
ation of rain waters.

Thus the necessity of a durable and lightweight element on which to lay the waterproof-
ing membrane; a material which would make the execution of adequate drainage slopes
easy, without overloading or compicating the structural components. Cementitious
mortars became the logical choice, but their weight often resulted in excessive burden
for the structure, so the idea somehow making these versatile materials lighter was
introduced.

Beginning with the incorporation in the mortar mix of naturally lightweight aggregates
(such as pummice: a porous rock of volcanic origin), the technology embracing mortar
weight reduction has since evolved greatly, taking many forms. Many have, in time,been
abandoned, either because of cost, predictability of results,long term performance, or
job site practicality.

By 1960, among accepted methods of mortar weight reduction, it was possible to iden-
tify three main categories :

1 . LOW FINES CONCRETE

Aggregate grading is selected so as to leave voids between adjacent stones. This


method could provide only very limited weight reduction, and therefore found only lim-
ited applications.

2 . LIGHTWEIGHT AGREGATE CONCRETES

Sand and gravel aggregates are substituted with natural or man-made aggregates of
lower unit weight thereby lowering the overall weight of the concrete.This method
offered greater weight reduction and very good mechanical strengths, eventually finding
its ideal application in prefabrication of structural elements. As roof fill it proved to be
unpractical due to high weight-to-strength ratio, excessive aggregate storage require-
ments, and undesirable water retention properties of some of the lightweight aggre-
gates.

3.6
3

A particular family of chemicals produces foam through a physical process which does
not require chemical interaction with constituents of the mortar matrix. The foam is
added to cement matrix. Its bubbles are trapped inside the mortar mix, and the over-all
weight is reduced. This method offered good weight reduction capacity and ease of pro-
duction on the job site. It promised to be the most suitable for roofing applications, but
performance in such areas as density control, compressive strength, and productio
capacity, still needs substantial improvements.
At this stage it was clear that the “foaming” method had good possibilities, and a
number of entrepeneurs set out on the complex task of not only selecting the proper
formulation for (”foaming agent”), but also to devise a complete system that would
transform production of “foamed” lightweight concrete into a practical operation,
capable of yeilding
predictable and satisfying results.
The research became oriented towards three very intricately related items:
The foaming agent, the production plant, and the technology of foam concrete produc-
tion and placing.
To be of any real interest to the industry, the system would have had to produce
acceptable densities and compressive strenghts within reasonable tolerances. Also, to
be really practical the mix would have had to be conveyable by pumps.
The first substancial step towards evolution of cellular concerte was the discovery that
preformed foams (chemical agents foamed seperately then added to the mortar matrix)
yeilded better results.

In a succesive step, basic requirements were set:

1 . The Foaming Agent would have to be:

A. Chemically inert with respect to the portland cement;so as not to interfere with the
cement's hydration process (on short terms), nor react with the crystalized cement (on
long terms);

B .Capable of generating air cells of uniform size so as to provide a "foamed" concrete of


uniform structure,important to guarantee strength, conductivity, and other physical
properties;

C .Easily mixed into cementous mixes;

D .Resistant to the rigorous stresses encountered during mixing, placing and surface
finishing of the foamed concrete;

E .Chemically stable so as to withstand storage for substantial periods of time;

F .Safe to be handled by all personnel concerned.

3.7
2 . The Production Plant would have had to:

A . Measure proper quantities of mix constituents, in a precise, and systematic


manner;

B . Homogenize the mix so as to guarantee continuity in the product performance;

C . Convey (or pump) the foamed concrete, from the place of mixing, to the place of
installation, without damaging the material;

D . Produce foam concrete in the substantial quantities.

3 . The Technology regarding foam concrete production and placing was expected to
guarantee uniformity of results regardless of ambien conditions, even if meant modifica-
tion under particular circumstances, of the characteristics of either or both the foam-
ing agent or/and the production plant.
Encouraged by a pressing market demand, many of the firms involved in the early devel-
opment attempts, proceeded to commercialize their first achievements, without having
a legitimate record of real and diversified experiences.

Code Description Unit of Sale Quantity Base Unit


agent Drum 210 Kg

4.3

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