Our company supplies foaming equipment, chemicals and technical support for foamed lightweight concrete blocks, panels, floor screeds, roof insulation screed etc.
We are Iranian company and have been supplying the technology for the production of lightweight foamed concrete, locally & worldwide.
We mainly do;
1) supply of foam generators & mixers.
2) supply of foaming chemicals.
3) training and technical assistance.
Other ancillary equipment to start production including, air compressors, mould system, mixers, pumps, are also available. Whole plant setup & other equipment needed for full scale plant can be obtained under our Technical Assistance program. We are quite experienced in export / import requirements of foam technology equipment for most countries & therefore can ship most of these equipment overseas.
However our technology is not just about equipment & chemicals but also know how & method in producing quality foam concrete. Therefore we place heavy emphasis on training & consultancy (Technical Assitance) especially for start-up, small & medium scale production and also for large scale plants.
Our methods of producing foam concrete is exclusive & tailored towards simplicity with low capital investment much lower than other similar systems or AAC (autoclaved aerated) plants. Our main equipment is user friendly, easy to install & maintain and available in various capacities depending on your budget. Most important, all our plants are designed to be mobile & can be dismantled or moved easily to another project location.
We also can send our basic equipment economically (since its portable & lighter than most other) to any part of the world.
In order for us to, advise you on the suitable equipment, chemical & type of technical assistance, please let us know about;
A) the type of product that you are planning and its intended application.
B) Its approximate size, weight or density.
C) The volume of production daily or monthly in terms of product numbers or cubic meters foam concrete.
Anyway attached are some information for you to consider. Further details such as pricing & specifications can be given upon studying your requirements. Please browse through the info attached and get back to us if you need more information or SMS or call if you like more info ( + 98 511 5420089)
Some of the areas where we can help you is in making;
A) blocks for wall construction.
B) panels for wall & fence construction.
C) geotechnical void filling, apron construction and road abutments.
D) arcitectural cornices, window sills and hood / canopy.
E) floor fill above rc concrete for level screed or insulation.
How Foam Generator work?
One of the most important ingredient required to produce foamed concrete is the aqueous stable foam.
The foaming generator acts as a medium which transforms the liquid chemical into stable foam. Foaming generators comes in many sizes depending on the ability to hold and transform liquid chemical into foam.
As an example , one would need about 500 liters of foam to make 1cubic meter of foamed concrete @ about 1100 kg/m3 density.
In order to make 500 liters foam , one has to dilute say 1 liter of chemical foaming agent in 19 liters of water and subsequently transform this 20 liters of premix solution into 500 liters of foam using the generator.
As you can see, the expansion rate is 25 times (550/20). We can increase this expansion rate by introducing more air but this will degrade the quality of the foam. Therefore the capacity of a foaming generator will depend very much on its ability to hold and pump out maximum amount of foam.
The typical foam generator runs from an air compressor and consists of a holding (filler) tank, foaming unit and a lance unit. The purpose of the holding tank is to hold the diluted foaming agent and subsequently deliver it through a foaming unit and lance. It is normally in a the form of a pressurised tank and needs to be closed tight for operation. The volume of foam obtained from such a system depends very much on the size of these tanks. For large volumes it is impractical to use the tank system since it is bulky to carry about. Large capacity holding tanks are heavy and cumbersome for smaller scale on site production. They are also attached to the foaming unit and lance in such a way that it would be virtually impossible to detach it for future modification.
Some foaming generators do not use a pressurized holding tank and makes use of a pneumatic or electric driven system to produce the stable foam. These generators are more versatile and are able to produce foam continuously. The are better suited to medium to large prodcution of foamed concrete.
Production of Foamed Concrete
The production of foamed concrete on a small scale is a fairly easy process which does not involve any expensive or heavy machinery and in most cases uses equipment that is already available for normal concrete/mortar production.
Depending on the volume of concrete required (normally limited to less than 20 cubic meters/day) one will only need ;
Equipment
1. Normal concrete/mortar mixer or special mixers for foam concrete.
3. Formwork (if producing pre- cast components)
Materials
1. Fine sand
2. Cement
3. Water
4. Stable foam
Simple Mix Design
The first step is of course to decide the wet density and how much foamed concrete you require.
Say volume of foamed concrete required = 0.5m3
Wet density of foamed concrete required = 1000 kg/m3
The raw materials required would be ;
cement = 200 kg
sand = 200 kg (assuming dry sand)
water = 100 kg (including water in foam)
then from the target volume of foamed concrete (0.5m3) calculate the air content and final foam volume in the mix.
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foam content in mix = 0.25m3 ( 250 liters ) |
If foam output from Portafoam = 1.5 lit/sec then one would need to pump generator for 250/1.5 = 2.77 min. The practical way would be to pump for 166 sec and add the rest of the foam using a measured container.
Mixing procedures
Now that you have worked out the amount of materials required to make the foam concrete add them dry first starting with the sand and cement. Mix dry constituents for a few minutes and add water in stages and make sure the mixing is thorough. Then add foam to the wet slurry and ensure foam has been completely mixed with the mortar.
After mixing is completed check that the wet density of the foamed concrete is close to what is required. The dry density (oven dried) of foamed concrete is normally less than its wet density, depending on w/c ratio, density and also on the cellular structure obtained. So do not forget to target a value of wet density much higher than what we actually require (dry).
