CLC Blocks made with (Profo) Protein Based Foaming Agent
CLC Blocks made with (Profo) Protein Based Foaming Agent are competitive with bricks in pricing and offer significant savings for finished structures. Savings in construction cost can be as much as 18% when using CLC Blocks, as compared to brick, after taking into account the resulting savings in gravel, cement, steel, labor, structure, foundation etc.
- Technology is simple and easy to execute
- Require minimum skilled workforce and primarily deploying unskilled labour
- Environment friendly – neither wasting natural resources nor creating pollution
- Economized on Energy Consumption
- Result in faster execution
- Finished dwellings are weather-proof, thermally comfortable and durable
- Suitable for Hurricane/ Earthquake –proof constructions
- Converting and make productive use of industrial waste products
- Cost effective in comparison with conventional alternative
CLC Blocks made with (Profo) Protein Based Foaming Agent are environmentally safe. They are bio–degradable and low toxic to the aquatic organisms.
Cellular Light-weight Concrete is very light colored. The addition of foam into the concrete mixture creates millions of tiny voids or cells in the material, hence the name cellular concrete. Although there is no direct path for water to pass through the material, an appropriate coating is required to prevent water penetrating into the CLC material. The quality of CLC production can be controlled accurately at the project site, just like Concrete. The surface finish depends upon the formwork and moulds used during casting.
CLC, like conventional concrete ages well, increasing its strength by as much as 50% (!) between 28 and 90 days after pouring, As long as CLC draws humidity from the atmosphere it will keep on increasing its mechanical properties. Curing takes place within the same period as conventional concrete. If cast in the evening, the concrete it could be demoulded the next morning. Curing can be speeded up by heat, steam or chemical (accelerators). CLC is an excellent and competitive material for low -rise, load-bearing construction and outside walls as well as partitioning work in multi –storied blocks.
Air is known to be the best insulation material available. Air voids, if smaller than 2mm each, consequently increase thermal insulation substantially. Normal aggregate concrete has a specific thermal conductivity (Lambda) of 2.1 W/mK, compared to 0.405 only for 1200kg/m3 cellular concrete. To offer identical thermal insulation as a 100 mm thick CLC wall, the equivalent thickness of dense concrete wall would have to be more than 5 times thicker (i.e. 500 mm) and ten times heavier.
Due to its high sound insulating properties it is used as a sound barrier between suspended structural floors, where its light weight and strength is a added advantage.
Fire and vermin resistance
Fire rating of cellular concrete is far superior to that of brickwork or dense concrete. Just a 100 mm thick wall of 1200 kg/m3 CLC, offers a fire endurance (heat transmission) of three hours. Moreover, there are no dangerous fumes or spread of fire as experienced with plywood partitions having rigid (styropore, urethane) insulation material – often the reason for loss of life of entrapped individuals due to toxic fumes during fires. CLC does not harbour or encourage vermin.
Durability and moisture resistance
CLC, like conventional concrete ages well, increasing its strength by as much as 50% (!) between 28 and 90 days after pouring, As long as CLC draws humidity from the atmosphere it will keep on increasing its mechanical properties. As a consequence of closed cellular structure of the material, the water absorption of CLC is lower, being in the range of 5% to 12%, depending on density. But it may require a surface protection to resist moisture penetration, affects of very harsh climatic conditions. Reinforced slabs were produced for tests in CLC of densities between 1000-1400 kg/m3, where the non-protected reinforcement was covered with 25 mm of cellular concrete. After four months, tests confirmed there was no corrosion on the 1200 kg/m3 specimen.
Toxicity and Breath-ability
Our protein-hydrolisation based foaming agent warrants high stability of the foam, successfully withstanding the manifold forces occurring when mixing, conveying (pump-able), casting and during the hydration process. The foam causes no chemical reaction in the concrete but merely serves as wrapping material for the air entrapped. It produces no toxic fumes or emission over its lifetime. Store-life of the foaming agent is guaranteed to be at least 24 months when adhered to instructions (before its integration into the concrete mixtures). However, CLC is a concrete product, and similar precautions should be taken as when handling and cutting concrete products. Personal protective equipment (such as gloves, eye wear, respiratory masks) is required during cutting due to the fine dust that is produced by concrete products.
Sustainability (environmental impacts)
In view the use of flyash 33% (an environment polluting industrial waste) being a major ingredient of CLC, CLC and this being a good substitute of ordinary clay bricks (which use high energy and precious agricultural topsoil) the Govt. of India has given special import duty concessions for specialized equipment. Its low density, good thermal and sound insulation and long life make it a good choice as a construction material.
Buildability, availability and cost
This lightweight concrete has higher consistency due to absence of coarse aggregate (gravel) and a ball bearing effect of the foam on the concrete is of great advantage for it flows by itself into the moulds and shuttering and any cavities, thereby doing away with the necessity of compaction or vibration. CLC is an air-cured lightweight concrete that can be produced at project site, utilizing equipment and molds normally in use for conventional concrete. Utilizing, the most traditional mixers and very successful truck mixers to produce cellular concrete, by installing and integrating a foam generator, into the existing concrete or prefab plants, with little investment and maintaining the production procedures being followed. However, a full range of stationary and mobile equipment to produce and precisely dose the foam, through a conveying system feeding sand and cement to a mixer, with highly effective horizontally operating screw and integrated concrete pump, could be sourced and setup to increase productivity.
The wide range in densities and consequently their different thermal and structural properties make CLC equally suitable for use: –
• As reinforced load-bearing in-situ walls and roofs in Low Rise Buildings.
• Even block-work (made from pre-cast blocks produced at the project site or obtained from a pre-casting plant) can also be used for load-bearing low rise constructions.
• Non load-bearing internal or external walls in High Rise Buildings.
• Thermal Insulation of building roofs and walls & roofs of cold storage.