Lightweight foam concrete blocks production process

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Foamed concrete, also called cellular light weight concrete is produced by the mixing of Portland cement, sand including or alone fly ash, water and preformed stable foam. The foam is produced with the help of a foam generator by using foaming agent. The air content is typically between 40 to 80 percent of the total volume. The bubbles vary in size from around 0.1 to 1.5 mm in diameter.

Foamed concrete differentiates from (a) gas or aerated concrete, where the bubbles are chemically formed through the reaction of aluminum powder with calcium hydro oxide and other alkalies released by cement hydration and (b) air entrained concrete, which has a much lower volume of entrained air is used in concrete for durability. Curing of foamed concrete unit may be done as per IS: 456-2000. Curing can be speeded up by steam.

Foamed concrete may be produce by mixing the above mentioned ingredients in ready mix plant or ordinary concrete mixer.

Foamed concrete is self compacting concrete requires no compaction, and will flow readily from a pump outlet to fill mould, form, restricted and irregular cavities. It can be pumped successfully over significant height and distances. The 28 days strength and dry density of the material vary according to its composition, largely its air voids content, but usually they range from 1.0 to 25.00 N/mm2 and 400 to 1800 kg/m3. The plastic density of the material is about 150 to 200 kg/m3 higher than its dry density.



Non autoclaved lightweight aerated concrete is a type of lightweight concrete which is used to produce blocks and replace bricks. NAAC is lighter then conventional concrete. It is formed by using portland cement, fly ash, limestone, aluminum powder and water. Aerated concrete has a good strength, durability, good thermal and sound insulation. Dry density of this material ranging between 600 kg/m3 to 1600 kg/m3. Non autoclaved lightweight concrete blocks can be used for housing and commercial purposes.


We have developed a unique non autoclave lightweight aerated concrete recipe and can achieve densities from 250 kg/m2 (even less) with perfect compressive strength, thermal and sound insulation.


PIONER GROUP supply lightweight aerated concrete infill for cold formed steel construction technology infill and we can supply dry mortars (plaster, floor screed, self leveling compound, lightweight aerated concrete dry mix etc.) production line with a good price and speed of delivery.