Dry mixture Cellular Fibro Concrete - a material from the Future
Cellular concrete is a lightweight cement-based material,
containing many gas bubbles, evenly distributed and representing
more than 20% of the whole volume of the material.
Compared with traditional concrete, cellular or porous concrete is considerably lighter.
Typical heavy concrete has a density of 2400 kg/m3,
while cellular concrete can be made with various densities from 250 to 1400 kg/m3.
The gas cellular concrete CFC is certainly the most convenient type of cellular concrete,
because it is produced from a prefabricated dry mixture.
The ready-to-use dry mixture CFC is convenient in application.
It can be packed in 25 kg bags, so that it can be easily moved by a single person.
It can be transported directly to the construction sites in cement trucks,
mobile silos, or special vehicles with built-in mixers.
Any concrete mixers, mortar-mixers or dry-mix mixers, existing on the construction market,
can be used for the preparation of cellular concrete from the CFC dry mixture.
The material can be prepared even in a simple bucket with a hand-held mixer.
The cost of CFC varies depending on the geographical zone
and depends on the different requirements.
As a general rule cellular concrete is much cheaper
than traditional heavy concrete.
Cellular concrete with low density is water-resistant and is extremely suitable
for application in the construction of the base of roads, for backfills in cutoff walls
in sea and river ports, in areas of peat grounds, wetlands and other weak grounds.
The dry mixture CFC is produced from mineral raw materials, from sand and
from waste products of the petro-chemical and metallurgical industries.
The mixture is produced from portland cement of any type: CEM I or CEM II.
The other main ingredient can be either sand or fly ash, or metallurgical slag,
which contributes to solving the problem with utilization of these waste products.
For the production of foam concrete are mechanically mixed cement, filler and
prepared-in-advance stable foam.
The difference in the preparation of foam concrete and gas concrete is that
the latter is produced with the help of a chemical reaction, which generates
hydrogen bubbles, creating many tiny spherical cells in the limestone-cement-sand mixture.
Mixing of the components with water produces aerated cellular concrete
with density varying from 250 to 1400 kg/m3.
The uniqueness of the CFC dry mixture technology is that there is no need
for a concentrated foam agent with water that would produce foam from compressed air
with the special equipment necessary for the purpose.
To prepare cellular concrete from the CFC dry mixture can be used practically
any existing on the construction market concrete mixers, mortar mixers or dry-mix mixers.
The ratio of water to dry mixture for preparation of the suspension depends on
the application and is determined by trial. As a rule this ratio is in the range
of 30 to 90 litres for each 100 kg dry mixture.
The intense mixing of the CFC dry mixture with water leads to the preparation
of the gas cellular concrete, which matures after it is poured, increasing its
volume 2 to 4 fold, and gets its initial hardness.
The mix of CFC with water is ready for forming of different construction
products: blocks for walls, overhead covering and partitioning slabs, arches, etc.
There are no special requirements for the water used. Drinking water with room temperature
can be used with no restrictions. Technical water, including water from the sea, can also
be used; it is however recommended to check its chemical composition first.
The cellular concrete from the CFC dry mixture is water-resistant.
It does not rot and is extremely durable. It can even float on water.
Strength and Volume weight
The strength and the volume weight of Cellular Fibro Concrete are interconnected.
The less the volume weight gets - the strength decreases,
the thermal resistance however increases.
In a CFC production plant it is possible to produce mixtures
with different volume weight varying from 250 to 1400 kg/m3.
For example cellular concrete
with volume weight of 600 kg/m3 has strength greater than 25 kg/cm2.
The used raw materials for the production of CFC
guarantee its safety for people and animal life.
During its exploitation cellular concrete does not emit toxic gases.
Its hygienic properties are second after the hygienic properties of wood.
The thermo-insulation properties of CFC
are 3 to 5 fold better, compared to those of regular bricks, and 15 fold better
than those of steel-reinforced heavy concrete.
Cellular concrete helps avoid hot temperatures during the summer
and reduces the expenses for heating in winter.
Fire resistance makes CFC the preferred material for roof and floor insulation.
It is perfect for building fire-proof walls or coatings.
The high fire resistance of CFC is determined
by its mineral composition and porous structure.
Application in roads, bridges, sidewalks
It is a well known fact that frost heaving, one of the main factors
for destruction of roads, bridges, tunnels and sidewalks,
is caused by the capillary migration of water and its freezing at low temperatures.
Weak grounds are another reason for destruction of structures.
The long experience, accumulated in Canada, the USA and England, in the application
of cellular concrete for construction of roads has proved its remarkable advantages:
* cellular concrete considerably reduces and in some cases completely stops
the influence of moisture on the structure (frost heaving);
* cellular concrete forms a harder foundation, if compared with gravel,
which is an obvious advantage;
* the weight of the structure is greatly reduced,
which is very effective on weak sand- and wet-lands, and in the same time
the thickness (depth) of the road foundation is considerably reduced;
* cellular concrete possesses liquid consistency
and the roughness of the soil surface is not of great importance;
* the depth of the ditch is immensely reduced;
* cellular concrete protects the foundation from softening in rainy weather.
Calculations by the Canadian company CematrixTM show that
the thickness (depth) of the road base can be reduced 5 times
in case cellular concrete is applied instead of traditional gravel.
As cellular concrete is lightweight it is simply irreplaceable in construction of
abutments to bridges, in strengthening of approaches and construction of
foundations under the bridge bearings, in bridge girders, in enforcement of
embankments and as backfill for supporting walls.
Application in construction of pipelines
Cellular concrete protects pipelines very effectively
from external forces (impacts, dynamic influence, etc.);
while at the same time it is a perfect thermo-insulator, which allows reducing
the excavation depth with an obvious economic benefit. CFC is also easy to cut with
any type of tool, including a hacksaw, and to pour in the places of repair, forming monolith.
Application in construction of sea and river ports
CFC is used in the construction of ports and moorings for backfills in cutoff walls.
As the material is lightweight, hard, resistant to deformation and water-resistant,
it has proved its obvious advantages in the process of exploitation.
Application in floors, walls, roofs
Floors of buildings are subject to different loads, wear and tear.
Floors made of cellular concrete are multi-functional. Cellular Fibro Concrete is a
reliable and long lasting material for floors with its water resistance, sound and
thermo-insulation qualities and lightweight. Floors of CFC are free of harmful
to man's health components. They are second after wood in hygienic properties.
They are heat and fire resistant and at 1000° C they last quite long
and do not produce harmful gases. Floors of CFC are easily repaired,
encapsulating pipeline, electric and other communications.
Roofs determine to a great extent the length of life of buildings.
Cellular Fibro Concrete, which is lightweight, possesses high heat and frost resistance
and good thermo-insulator qualities, turns out to be a very suitable material
for the construction of flat (level) roofs.
CFC replaces the traditional multi-layer "pie" of flammable roll materials.
The CFC dry mixture opens an even broader range of applications
in the construction of houses, cottages, etc.
Welcome to the world of nature-friendly construction materials,
to the world of Cellular Fibro Concrete!
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