- Reduces the dead weight of a structure.
- Can be manufactured to precise specifications of strength and densities.
- Possess excellent workability.
- Can be nailed, planed, drilled and sawn.
- Provides excellent heat and sound insulation.
- Can be applied with all traditional surface finishes – paint, tiles, carpets etc. ;
- Moisture resistant and Fire resistant.
Weight Reduction
Foam concrete density ranges from 250 to 1800 kg/m3, as compare to 2400 kg/m3 for conventional concrete. Therefore, the weight of a structure built of foam concrete would undoubtedly be reduced significantly.
Thermal insulation
Foam concrete with a density of 1200 kg/m3, for instance, can produce a monolithic wall 5 times thinner and require 10 times lesser raw material (by weight) and possesses 5 times superior insulation properties compared to that of conventional concrete. The amplitude-ratio and phase-displacement of a 15 cm thick wall with a density of 1100 kg/m3 causes the outside temperature of a building to take between 10-12 hours to reach inside. Such a duration, which is much longer than that of conventional concrete wall, results in the foam concrete being naturally air-conditioning.
Fire rating
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In 1100 kg/m3 density LCM, a 13 to 14 cm thick wall has a fire endurance of 5 hours. The same degree of endurance is achievable with a 400 kg/m3 density LCM of only l0 cm thick. LCM is non-combustible and the air-embedded in LCM attributes to the high fire-rating.
Sound insulation
LCM is a perfect impact and air-borne sound absorbing concrete and hence, highly suitable for party walls and floor screeds / foundations.
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Reduction in dead weights contributes substantially to savings in reinforcing steels in foundations. The dimensions and therefore, the overall quantity of steel reinforcement in LCM can be reduced by as much as 50%. Savings are also substantial in transportation, crane-and man-handling related activities as well as in raw materials, as no gravel is required to produce LCM but only sand, cement, water and air, with the resulting mortar/paste subsequently embedded in the foam. Casting very slender walls can optimize the amount of concrete used, and some of our consumers had produced walls as thin as 50 mm thick. The high flow ability of LCM makes vibration unnecessary, and thus requires no prescription of vibrating equipment/accessories.
Savings in manpower
Only a few semi-skilled workers are needed to produce LCM concrete for casting / pouring of panels, blocks or even complete walls for houses. In producing LCM, steelworks, formworks, brick laying and cement renderings do not constitute major site activities, and therefore the related workers are not required. Workers are only needed to set up cost saving and reusable formworks, and for removal of formworks for next erection / casting.
Glass and Steel Fiber addition
Mixing randomly distributed short fibers in LCM results in a three-dimensionally reinforced matrix. The fibers have the effect of increasing the static and impact strength, reducing early-age cracking and also reducing water absorption.
Compressive Strength
An average compressive strength of 2.86 MPa has been achieved on a 650 kg/m3 density LCM cubes following 28 days of standard water-cure. Tests done to date on other densities revealed that 28-day strength exceeding 18 MPa is achievable depending on the density of the mix. Studies also show that compressive strength of above 20 MPa is obtainable with the addition of short fibers and steel mesh reinforcements.
Life span of Foam concrete
Foam concrete has a life span of above 100 years. Previous investigation has shown that sectioned blocks of foam concrete cast 10 years ago indicated only 75 percent of the cement hydrated. It is expected that the strength would continue to increase with continuing hydration. The use of LCM in many cases makes additional man-made products like clay bricks and other insulation materials out-dated.
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No special skill is required in applying the system. It is fully adoptable or at least adaptable into existing concrete or prefabrication plants, adding only the LCM Foam Generator to produce and discharge foam of a precise dose into the mixer. LCM may later be pumped using conventional concrete pumps. Due to the absence of gravel and the ball-bearing effect of the foam, LCM possesses a high degree of flow ability. No vibration is thus required and LCM completely fills all gaps and voids in the concrete or mould, fully embedding any hoses, tubes, frames for windows and doors.
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The rapid mixing and high fluidity of LCM facilitates speedy casting of building elements. With the application of vertical molds to cast complete houses in place, omission of vibrating equipment results in the entire walls and ceiling/roof of a building being filled in one step. Openings (or the actual frames) for doors and windows, and ducting and conduits for sanitary and electrical services can be cast in place and firmly embedded in the foam concrete.
Foaming agent
LCM foaming agent is based on a protein-hydrolisation and is bio-degradable. It causes no chemical reaction with the surrounding matrix but serves solely as wrapping material for the air to be encapsulated in the concrete (mortar).
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Only sand, cement and water are mixed in accordance with the design-mix charts recommended by LCM that take into consideration suitable property-enhancing materials like fibers and other pozzolan and/or cementitious products. The water-to-cement ratio must be strictly followed since too little water might cause the cement to draw its requirement from the foam, causing the latter to collapse partly or in total. The extremely high stability and stiffness of the LCM foam allows any density of LCM concrete from as low as 250 kg/m3 to 1800 kg/m3 to be produced with an optimum ratio of strength-to-density. The possible wide range of densities achievable thus offers multiple and diversified applications, such as site mixing, off-site mixing, prefabrication, pre-cast or cast in place.
Curing
LCM requires curing means and period identical to that of conventional concrete. It is essential as in conventional concrete, that cement-based elements need moisture for hydration at an early age. This is particularly true in the presence of direct sunlight that is known to cause rapid dehydration of concrete surfaces and that curing compound can be applied as an alternative barrier.
Skim coating
LCM requires no plaster (as in sporex-type cellular concrete), and a usual water-repellent paint suffices. However, where desired, LCM can hold plaster very well, offering superb adhesive properties. It is also possible to apply wallpapers directly onto the surface. Nevertheless skim coating is highly recommended with LCM.
Popular applications
LCM of density 300 kg/m3 offers the only system worldwide to produce a solely mineral-based insulation board with the same insulating properties as man-made polystyrene, polyurethane or mineral wool, with no hazardous elements to health, environment or fire.
LCM of density between 250 – 550 kg/m3 is primarily used for thermal insulation or fire protection. It uses only cement (or with a small proportion of sand), water and foam and can easily be pumped into moulds of varying orientations.
LCM of density between 600 – 800 kg/m3 is used for void-filling, such as in landscaping (above/underground construction), filling voids behind archways and refurbishing damaged sewerage systems, as well as producing masonry units.
LCM of density ranging from 800 to 900 kg/m3 is primarily used in the production of blocks and other non-load bearing building elements such as balcony railings, partitions, parapets, etc.
LCM of density ranging from 1100 – 1400 kg/m3 are commonly used in prefabricated and cast in place walls, either load-bearing or non-load bearing. It can also be successfully used for floor screeds.
LCM of density between 1600 – 1800 kg/m3 would be recommended for slabs and other load-bearing building elements where higher strength is obligatory.
Minimum Investment
As conventional concrete and prefabrication plants may be used to produce LCM, the only investment that would be necessary is in the inexpensive foam generator and the foaming agent.
