cellular lightweight concrete manufacturing process and Applications

Cellular concrete is also known as Low-Density Cellular Concrete(LDCC), Cellular Lightweight Concrete(CLC), and Foamed Concrete. In this article, we will cover the clc blocks manufacturing process.

clc blocks manufacturing process

Cellular concrete is the introduction of air into the concrete mixture. Air entrained concrete is created when small air bubbles are introduced as an addition to the concrete mixture.

The addition increases workability and once hardened, concrete becomes more durable with less cracking, shrinking, and weather resistance.

The density of cellular light weight concrete ranges from 400 kg/m3 to 1600 kg/m3.

Raw materials

The main Ingredients for the clc blocks manufacturing process are;

  • Cement
  • Fly ash
  • Foaming agent
  • Sand (optional )
  • water

Example mix: For 1 cubic meter of ALC concrete of density 850kg/cubic meter take,( approx..) Water: 200 liters, Fly ash: 500kg, Cement: 5 bags of 53 grade, Foaming agent + water = 1.2 kg + 30 litres

Classification Based on the density

Based on densities the cellular lightweight concrete is three types namely, High density, Medium density and low density concrete.

  • High-Density cellular concrete Its density will range from 1200kg/m3 to 1800kg/m3 and used in the construction of load-bearing walls.
  • Medium-density cellular concrete Its density ranges from 800kg/m3 to 1000kg/m3. Its major use is pre-cast blocks for non-load-bearing brickwork.
  • Light density cellular concrete Its range from 400kg/m3 to 600kg/m3. They act as resistant against fire accidents, termite and moisture absorbent.

Equipment required

Following are the equipment used in clc blocks manufacturing process;

  1. Mixer
  2. Control panel
  3. Load indicator
  4. Foam generator
  5. Air compressor
  6. Belt conveyor
  7. Trolley
  8. Molds

Read Also: AAC Blocks Manufacturing Process

CLC Blocks Manufacturing Process

  1. Foamed concrete generally consists of a slurry of cement or fly ash, sand, and water. But some suppliers recommend pure cement and water with the foaming agent for very lightweight mixes and sand is ignored.
  2. This slurry is then further mixed with a synthetic aerated foam in a concrete mixing plant.
  3. The foam is generated using a foaming agent, mixed with water and air from a generator.
  4. The foaming agent has to produce air bubbles with high stability and resistant to the physical and chemical processes of mixing, placing and also hardening
  5. Foamed concrete mixture is directly poured or pumped into molds.
  6. This viscous material requires nearly 24 hours to solidify and also depending on other factors including ambient temperature and humidity.
  7. Once solidifies, the formed blocks will be released from the molds.
  8. These are cured in an open area for at least 15 days of time to gain its full strength.

Applications

  • The lightweight foamed concrete blocks are mainly used for the construction of partition walls.
  • From the lightweight nature of the blocks, they impose a minimum load on the structure.
  • Foamed concrete blocks provide good thermal insulation and also sound insulation.

Size and cost of CLC block

The cost of CLC is around 1900/per cubic meter and based on the different sizes in CLC Blocks, the rate per block varies

For the latest price visit the site: India Mart (we are not sponsoring any product and it is only for information)

Size in MMMM Size in inchesWeight in KgNo. of blocks per cubic meterRate of each block
600 x 200 x 100mm24 x 8 x 4” 10 83 22.89/-
600 x 200 x 150mm24 x 8 x 6” 15 55 34.55/-
600 x 200 x 200mm24 x 8 x 8” 20 4146.34/-
600 x 200 x 225mm24 x 8 x 9”243751.35/-

Advantages

  • CLC blocks are Lightweight
  • These blocks are Fire resistance Also Thermal insulated.
  • CLC blocks are Environmental friendly and Cost-efficient.

Disadvantages

  • As compared to AAC blocks CLC have less strength for the same density of the material.
  • The size and strength of CLC depend on batching and curing conditions at the plant and are not accurate for all the blocks.
Watch this video for detailed explanation

Codebooks for references:

  • ASTM C 869
  • ASTM C 769
  • ASTM C 495

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K Vinay Goud

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