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Density can be adjusted to whatever is needed, often times based on desired strength. Using Type 1 Portland and water for the base slurry, you typically won't find wet cast much below 30 PCF, however it is possible. Going with a 30 PCF wet density will yield a dry density of around 25 PCF and on average 100 psi compressive strength. Lighter will be weaker and can be more challenging to have the bubbles stay in tact long enough for the cementitious mix to get a "set".

Is the question how high will it flow/pump? If so, there are many factors to consider; pump type/pressure capability, hose size, hose/tube diameter, pumping rate, material density, among other things.......That being said, we've used our equipment to pump nearly 100' vertically through a 3" steel pipe with 35 PCF material. That was approaching 125 psi of pressure on the foam injection circuit. Being able to pump higher with our equipment is possible, but there are many things that would need to be considered. If using to abandon wells and simply needing to gravity feed the question changes, but becomes simpler to answer.

Cellular concrete can produced in a wide variety of densities. Referencing ACI 523.1R, cast in place low density cellular concretes having an oven dry density of 50 PCF or less. In most applications within North America, which are primarily geotechnical, densities will often times be between 25-40PCF. I believe the material you see being produced in the video is approximately 35PCF.

According to ASTM C90 CMU blocks need to have a compressive strength of 2000 psi. Achieving that strength with cellular concrete is difficult while still achieving much weight reduction. It may be possible to reduce weight of a 140PCF material by as much as 20%-30%, but to still meet 2000 psi you'd need to start with higher strength material - which will have a higher Portland content relative to any course or fine aggregates in the mix. Other high performance cemtitious materials could be used as well. However either of these scenarios means the cost of the material will be higher and by the time you add in foam (which is relatively cheap ~ $10yd³) you may not realize any cost savings. If there are other benefits to be gained i.e. increased insulation, reduced trucking, reduced labor, etc.. it's possibly still worth it. The details of that answer can be highly dependent on the application. AAC of course is an all together different process and produces materials that in general have a higher compressive strength for any given density. Referencing the answer to your first question, it's possible to produce "cellular concrete" with higher strength/performance than most of what's produced for geotechnical applications today, but that can be a time intensive process.

Yes, quantifying fresh Portland is something that can't be easily done - unless you're getting lot info from the manufacturer maybe. However in the context of how we use the term, if you're able to get Portland from a ready mix plant (which also may not be easy) you can make a fairly high assumption it's going to be as "fresh" as you can get, given how often most of them would be receiving new loads of Portland.

Rotor stator pumps or peristaltic pumps are going to work best. If you're not using any aggregate (course or fine) a rotor stator pump is usually favored because they're typically more economical to purchase, and smaller in size. Also, they provide a very smooth continuous flow (without the use of a pulsation dampener), which for some applications is needed or preferred. Peristaltic pumps require less maintenance however and can handle fine and course aggregates much more easily and without the risk of severe wear and damage. They are more expensive to purchase, much heavier, and as whole take up more space.

I'm guessing you were referring to the last part of the video? If so, you're right on! We did have the air and water pressure set artificially and going through a restricted nozzle, simply to create the effect in the video. We were just creating a different foam for the visual effect, but of course did not point out it wouldn't be an "ideal" foam for producing cellular concrete.

Our CMX foam formulation is synthetic, as is much of what's used in the industry today.

It was originally designed for mixing and pumping gypsum floor topping materials. Although it would work very well for mixing and pumping cellular concrete, you'd still need a foam generator. Also, because of the automation and technology that was designed into the machine there may be more cost effective options out there, depending on your needs. Feel free to call us at 800-553-2404 if you'd like to discuss further. Thanks -- Tony

We manufacture our own foam concentrate that was designed for use in cellular concrete. I'm not quite sure what you mean by "killing the cement"? Generally speaking surfactants (foam) will act as a retarder to the hydration process, but to my knowledge it won't stop hydration of the cement from occurring. If you're having trouble with your cellular material getting a set, or air bubbles collapsing, I'd guess it's one of two things; your foam concentrate isn't able to sustain bubble integrity long enough to allow the cement to get a set, or you've got old cement. Buying bagged material from the big box stores is something we don't recommend. Humidity in the air can start the hydration process from the day cement is produced and over time the cement will "go bad". If it's old enough the cellular concrete you've just produced can actually have bubbles collapse -- no matter what foam you're using. If you've got further questions feel free to call us at 800-553-2404. Thanks! -- Tony

We only manufacture the loader, and not any attachments. However there are backhoe attachments available that would fit on the SCL-210. Pricing is of course dependent on the options. Give us a call and we'd be happy to discuss these with you! 800-553-2404

Using a concentrate designed specifically for cellular concrete will improve the results you're getting with your method. Using an "externally generated" foam would be more consistent, but if you're only wanting to do this for one or two pots may not be worth the effort and money to buy and or build. You could consider using styrofoam beads to reduce the weight. Not to up sell a competing product, but for this application (again if it's just one or two pots) it may be a simpler way to achieve what you're wanting to do.

@@RichwayIndustries1 thank you for responding. Just to get clear, are you saying that I would get better results using a liquid designed for making foam to mix with concrete .. and also using it with my drill and paddle (as I had tried to do with the Suave) .. but if I want to ensure a good foam, I’d need a foam generator (which, I agree, I don’t want to invest in) .. but .. my best solution may be styrofoam balls? So .. I guess you all have tested making the foam with a paddle attached to a drill and it doesn’t get to the same density as the foam generator machine does? Thanks again.

Typically rotor stator pumps and peristaltic pumps are used in the production of cellular concrete. The short answer is if you're wanting to use sand, I'd look at using peristaltic pump. Rotor stator pumps will not handle large aggregate well and can be subject to accelerated wear when using sand. Peristaltic pumps can be more costly upfront and consume a lot of power. However they'll handle any types of aggregate very well. Swing tube piston pumps can be used, provided the valve clearances are tight on the S-tube and cutter ring, but if they're not you can expect a lot of density increases because air will get squeezed through the gap back into the hopper. Ball check piston pumps can be used, but if trying to pump material that's already got foam in it, the ball valves may "float" (due to buoyancy caused by the cellular concrete) and not seat properly, causing little to no pumping to occur. If you're doing in-line injection of the foam, rather than batching before pumping, you can avoid exposing the foam to the shearing action that some pumps types can have.

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I'd start with a slurry mix of Portland and water using a water:cement ratio of .50 - .60. Adding sand will create a weaker (in terms of compressive strength) material. To make that up you'd need to make a higher density, which in turn will drive the cost of the material up, offsetting the economics of using sand.

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In general, the density of the foam won't have an effect on the material once it's gotten a set. The purpose of the foam is to create an air void matrix in the slurry. After it's gotten a set, the foam no longer exists and has served its purpose. That being said, the foam still needs to "survive" the mixing, pumping/placement, and setting process. With our foam concentrate and equipment we recommend a foam density of 32-48kg/m³ and a water to concentrate ratio of 40:1 - 50:1. We'll be publishing a video describing foam density and water to concentrate ratio in more detail in the next few weeks.

There are many factors to consider; the density of the material being pumped, the mix design of the slurry, using a foam concentrate that is designed for producing cellular concrete, the pump pressures, and of course the type of pump. With all factors understood and controlled, cellular concrete can be pumped long distances with little to no change in density.

Are you referring to the foam itself?? If so, the water to concentrate ratio ranges typically from 40:1 to 50:1 (when using our CMX foam concentrate). The density of the foam itself ranges typically from 2 PCF - 3 PCF (32-48 kg/m³). To get a thick, consistent foam with small bubbles requires the proper equipment. You must be aware of your water flow rate, air flow rate, and be able to keep them consistent. Simple equipment can be used for testing and small scale production. I've seen simple machines constructed of PVC pipe/valves that can create effective foam. Much of the equipment we design and build is geared towards large scale production -- as much as 75 m³ per hour. You must also have a good quality foam concentrate to be successful with cellular concrete. Foams that are designed for producing cellular concrete will allow you to create lighter materials while placing deeper lifts, with little to no shrink or collapse. The last thing is a must --- use FRESH Portland! Even with the best machines, foams, mixers, etc.. Portland that's been sitting on a shelf will create a weak material at best. At worst, it'll collapse before it even gets a set. Best of luck!

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The density of the cellular concrete in this video is about 35 pounds per cubic foot ( 560kg/m³). The slurry being used, before foam is added, is simply Type 1 Portland with a .5 water to cement ratio. The density of the slurry is 114 pounds per cubic foot (1830 kg/m³). Taking the starting density of 1830kg/m divided by the ending density of 560kg/m we have an expansion ratio of 3.26. So every m³ of slurry yields 3.26m³ of cellular slurry, after foam is added.

It's a neat idea. Over the years we've worked with a lot of people who've worked on building projects using cellular concrete in North America. One of the greatest challenges is that as cellular concrete gets lighter in weight, it also becomes much weaker ( in compressive strength/tensile strength), relative to "normal" concrete. A 30 PCF (pounds per cubic foot) material has a compressive strength of about 100 psi. Full density concretes weigh usually about 145 PCF and ranges in strengths from about 3000 - 8000 psi typically (they can go much higher, but become what I'd consider less than typical mix designs). If pre-casting logs, mold turnover time becomes critical, which works against low strength material because demolding a delicate material can be challenging. Fibers, reinforcement, admixtures can help, but also drive the price up. En masse, it's not apparent that the North American home market is able to support using cellular concrete for building homes ---- yet. It's probably coming though. A good push from architects, engineers, and buildings and codes revision would help!

@@RichwayIndustries1 Has anyone tried ading fiber to the concrete. small wire mesh?

We've used a variety of fibers and have found that many of the benefits that fiber provides to "normal" concrete also apply to cellular concrete.

We do have a mix design calculator available for free download on our website that is very useful in creating mix designs. However if you need help beyond that, you're welcome to call us or email us at anytime. Thanks!

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