Monolithic foam concrete - Theory and Practice

Becoming more common in the private sector gets the monolithic housing construction, but if the classic reinforced concrete in different variations is no surprise, then foam is much rarer. And this despite the fact that the technology itself was developed in the early twentieth century, and the characteristics of the material is quite competitive. But if someone does not even heard of it, the members of our portal FORUMHOUSE already lined up from it and share their experience with anyone who is interested in this topic.

foam concrete

Foam - a kind of cellular concrete technology for the production of artificial stone invented back in the twenties of the last century. By major parameters it is as close to natural wood, is lightweight, environmentally friendly material with low thermal conductivity. Such characteristics it acquires due to the porous structure - when added to the cement-sand mixture or the finished foam when mixing the solution with a foaming agent. Since in both cases the process is accompanied by thorough mixing of the components, the air pores are formed uniformly throughout and after solidification homogeneous structure is obtained.

Made of foam monolith blocks or poured in a removable or non-removable formwork. Depending on the density and strength of the mass, the material used for thermal insulation (protecting design of overlapping first and other floors), and as a construction for erecting load-bearing walls. Due to the minimum thermal conductivity of monolithic foam wall do not require additional insulation and structural strength is provided by using a material density of not less than D600. In addition, as a reinforcing additive in the solution is introduced fiber, but for secure samozastroyschiki used when pouring and traditional reinforcing cage and high mesh.

One of the limiting factors for the widespread distribution of houses construction technology of monolithic foam concrete is a process for its manufacture - requires special equipment. for private application and fill the relatively small amounts usually used compact mobile baroustanovki. They allow to mix more dense solution with lower water content relative to cement, which further reduces the shrinkage. All components in strictly defined ratios are placed in a sealed mixer, to the same air under pressure is supplied. After kneading enriched air mass discharged into the mold. Similarly, the unit for the construction of his house took one of the craftsmen from our portal, its experience and notions will be useful to everyone who thinks about this wall materials.

Monolithic foam concrete, or build "without money"

Of course, the topic we are not talking about the wonderful technology that does not require financial investment, but a real experience of economical construction on its own.

fugi1 (User FORUMHOUSE):

We will build the house of monolithic foam concrete, and I will try to describe the processes, all the successes and mistakes, the benefit of any experience, I think that would be helpful. Construct without money, of course, also possible, but no more than a hut, because "no money" means to build on normal pay ordinary worker without the revenue side, managing to make the most economical, but with high quality and on conscience. You want to do well - do it yourself, so do everything yourself.

Start from scratch - buy a suitable site, in order to bring it by eliminating weed alignment imported soil tillage portion and a vegetable garden. Battle for electricity by 550 rubles (official cost of connection), which ended in victory, albeit with high costs, clogging of the well (namely clogging of the perforated pipe along the ground to the aquifer layer). Cellar under the house, in which the well is made, initially topikstarter tried to dig by hand, but in the course of this efforts to combat learned that saving is worth wisely and in some cases much better to draw technique.

fugi1:

Save money by trying to do everything yourself is not always true - in the end may come more expensive than taking the time to simply earn money and hire a tractor, a car or other equipment. It is necessary to consider all must be considered!

However, it is about hiring equipment, the hiring of the workforce fugi1 It refers negatively.

fugi1:

On the involvement of workers we must also consider the part if I paid for the same time as much as they, working in me, what's the point that I take the same amount shifting from place to place and eventually get a job unknown quality?

Therefore, all the processes of construction, he decided to carry on their own, occasionally calling on the aid of his brother, and with all possible assistance to the couple.

Foundation - recessed 80-90 cm band (trench digging tractor), and the same pedestal protrudes above the ground level, sand cushion, the reinforcing cage (overlap on the meter, the whole angle, bent). Samomesny solution, but all the ingredients were weighed carefully, no "by eye". Plus, modified plasticizer - additive to improve not only performance indicators, but also the properties of ready-mixed concrete, and now craftsman without any solution will not start. In the course of the process was invented by way of delivery of long reinforcement without the involvement of specialized equipment - a car with a "halo". In the winter of land left enclosed, with light, flooded basement and foundation.

Monolithic foam concrete - self-supporting material, but fugi1 decided to play safe and to fill in a few of RC columns and join them after the RC beams to them lay the load of the ceiling and roof system. As formwork/ Form used cut pipes, fixed parts with aluminum brackets and screws with washers. Reinforced column four reinforcing rods, poured layers (shear peel cement and washed) to give pillars of 2.8 m in height and 15 cm diameter.

Under the monolithic slab floors poured into the formwork support posts of the CAP (15 pieces), voids filled screenings, reinforcement armature and road grid formwork of metal tubes (60x40 mm), the tube Zaglada surface. Stove both draft floor, underneath all communications.

Plant for the production of foam concrete chipped bought with his brother, the choice of this material is explained by economic expediency.

fugi1:

Why foam? Because the estimated full cost of the wall: wall decoration inside, insulation, finishing outside labor for the construction, value for insulation and heating costs in the future. And it turned out that it is cheaper to buy the installation formwork and consumables than putting a wall of concrete blocks, plus facing anything, plus buy a heater, and then spend a lot of time and health on construction walls.

In order to avoid cracking of the concrete due to shrinkage and rapid drying in the sun, craftsman came up with a simple but effective drip irrigation system. First plate used to maintain humidity, after - for protection against cracking of the walls.

fugi1:

Found once bought a mechanical daily timer, graduation - 15 minutes. I put it on the old water valve with a washing machine and connected it via a timer, which put on the time of day: more often during the day, at night once. I bought 150 meters of pipes for drip irrigation, to connect it to the valve, and the day after pouring in the morning, laid out on the fresh concrete. Everything! Now the concrete hydrated all the time!

Furthermore timer improvised craftsman built vibroseyalku for sand because of its quality parameters of the solution will depend largely.

fugi1:

For vibration picked up the old motor with the outdoor unit of a split system (35W-220V), it put a piece of the oxygen hose and tied weights, a circle made defense, suddenly fly off. fragility legs replaces suspension springs.

Decking of waterproof plywood (dissolved the sheets in half), as metal fasteners Area, spacer pieces of plastic pipes, shuttering pulled together initially binding wire, fixed on two self-tapping screws. On the advice of one of the participants in the discussion later began to use metal studs. plant capacity allows to fill the walls at an accelerated pace, but slows down the process of rearrangement of timbering. If you use non-removable, or to invest in large pieces (full list), it will go faster.

Solution fugi1 made prescription products installation - and the layout and proportions. The only exception - softened water (tough), soda ash, as recommended in the instructions to the foaming agent. The consistency of the test solution produced a jelly-like, with no solidification shrinkage and bundles.

The exact composition of the mixture to fill the walls:

• warm water - 25 liters, with hard water with the addition of soda (280 g / mᶟ);
• fiber - 120 grams (about the bank's half-liter, slightly compacted);
• a foaming agent (PB-Lux, PB-2000) - 75 g;
• accelerator plasticizer (Fort UE 2) - 240 g of a solution bag (20 kg) was diluted a hundred liters, obtained 200g / l;
• Cement - 37 kg;
• clean sifted sand (the smaller the better) - 36 kg.

air pressure - not more than 0.6 atmospheres, stirring for 3-5 minutes, discharging.

To prevent capillary leak, first plate covered with a layer of bituminous mixture (cake lit gasoline) after fusing roofing waterproofing layer (a wall, a column bottom too bitumen, insulation). Reinforcement monolith road grid (3 mm, 10x10 mm) overlap with one rod and fixation binding wire, the thickness of the protective layer - 2 cm from the indentation slopes - 5 cm.

The walls were filled in stages, since the construction was carried out in a single helmet and in the evening, at night, after work. Saved from cracking drip irrigation, for coupling the layers carefully smooth out the surface. To the solution is flowed through the gap was filled in a small layer (10-15 cm) under pressure from above, first around the perimeter of the casing, which is just slightly "grab" until all the filled form. After carefully poured the remaining volume, if there were losses, the minor. The solution is plastic, holds its shape well, does not spread.

Openings for future sills flooded, putting the formwork to the required level, the concrete surface is carefully smoothed, after stripping Stripping of milk, moisturizing and "iron". Above the openings poured reinforced bridge of heavy concrete for the walls of bundles with future partitions in the joints embedded in the walls of the grid.

Fill the box at almost one helmet took 50 days - work in the evening and at night, there were also delays due to weather and force majeure.

Laying nets also poured fragmentary skeleton of the three reinforcing rods, with extension of the corners overlaps (more than a meter) on the walls, the walls ligament specifically released grid. Wooden formwork solution - cement, sand, stone 1 / 1.7 / 2.3, fiber (120 g) not to komkovalas, gradually fill up and fluff. The role played beacons open edge formwork (board height 15 cm), top film. The new fragment was filled, yet walked the setting process, a day, after rearranging the formwork, in such a method loss of strength compared with a monolithic casting negligible.

The next stage - beams of the ceiling, truss system, installation of windows, entrance doors, metal, shading walls and further improvement.

As for the technology, it is very time-consuming - the main problem is not in the cast, and in the permutation of formwork. If you use non-removable, it will increase costs, but will save time and effort. And yet, fugi1 selected method satisfied.

fugi1:

If the person asked me how I did, I would still chose a monolithic PB, even with all its difficulties. In each method, and the method has its charms and its sorrows, and a monolithic PB of sustainability - it is almost like a tree, but does not burn.

All the details and lots of other useful information at least - Topic author, Another example of the construction of the foam - in the subject line "Building a house made of reinforced foam ..." the participant with the nickname of the portal Tagan1. Video the house of permanent formwork technology - to understand approximately what it was about, let alone reproduce and can be made of aerated concrete with plywood or any other lining.

Discuss the article and read other materials devoted to country life you can on the websiteFORUMHOUSE.

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