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Foamed concrete typically consists of a slurry of cement or fly ash and sand and water, although some suppliers recommend pure cement and water with the foaming agent for very lightweight mixes. This slurry is further mixed with a synthetic aerated foam in a concrete mixing plant. The foam is created using a foaming agent, mixed with water and air from a generator. The foaming agent must be able to produce air bubbles with a high level of stability, resistant to the physical and chemical processes of mixing, placing and hardening.

Foamed concrete mixture may be poured or pumped into moulds, or directly into structural elements. The foam enables the slurry to flow freely due to the thixotropic behaviour of the foam bubbles, allowing it to be easily poured into the chosen form or mould The viscous material requires up to 24 hours to solidify (or as little as two hours if steam cured with temperatures up to 70 °C to accelerate the process., depending on variables including ambient temperature and humidity. Once solidified, the formed product may be released from its mold. A new application in foam concrete manufacturing is to cut large concrete cakes into blocks of different sizes by a cutting machine using special steel wires. The cutting action takes place before the concrete has fully cured.

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WHAT EXACTLY IS FOAM CONCRETE?

Foam concrete, also known as aircrete, is a type of lightweight concrete typically made by mixing water, cement and foam. Sand may also be included to make the mix stronger. The different components added to the mix will determine the strength and durability of the concrete. Lightweight foam concrete may also be made using Portland cement, limestone and/or pulverised fly ash.
Foam is just one of many types of alternative concrete mixes. At Total Concrete, we can create the perfect mix to suit your needs