Foam Concrete Coimbatore
Foam Concrete Services in Coimbatore
Our Economical Concrete Foam Solutions in Kerala
Foam concrete is a highly workable material rich in air bubbles, usually produced onsite and pumped into place. Lightweight, low-density fill material has the ability to flow into any void, hole or backfill and can be pumped with ease due to its high fluidity. It’s also versatile enough to be used for a variety of applications and can be formulated with added features such as drainage capabilities.
It is an ideal material for construction where the weight of the building should not exceed the load-bearing capacity of its foundation or reduce the dead load on the structure. Hence it is very useful in seismic prone zones.
What is Foam Concrete?
Foam concrete is a lightweight, low-density fill material that can be used for many different construction applications. It’s well suited for trench backfill and blindside walls, subgrade filling, stabilizing soft soil deposits, void fill, backfill to retaining wall systems and even barrier walls. Foam concrete can also be made with a high pore content to allow drainage applications. Our foam concrete service is fast and economical because it can be pumped into any space – no matter how tight or awkward! Here’s how foam concrete is made: Normal concrete has three fundamental ingredients: cement paste/mortar (mineral filler plus water), sand, and coarse aggregates (stone). Water is mixed with Portland cement powder in the appropriate proportions and then mixed with foam until the slurry has a soupy consistency. The foam acts as a fine aggregate.
When foam concrete is combined with engineered earth materials, such as crushed stone or infill, its properties are enhanced. The flowability of the mix allows the placement of more of the engineered earth material in any given volume compared to traditional concretes made from mortar only. In contrast to other known foamed concretes, this mixture maintains its structural integrity long enough.
Properties of Foam Concrete
Foam concrete is a cement-based slurry with a minimum of 20% (per volume) foam entertained into plastic mortar. Foam Concrete mixture can be poured into moulds, or directly pumped into structural elements. The foam enables the slurry to flow freely due to the dynamic behaviour of the foam bubbles, allowing it to be easily poured into the chosen foam.
Foam concrete is a type of lightweight concrete, in which a foaming agent introduces air. The density of foam concrete can be reduced by creating gaps in hardened cement paste. These gaps or voids can be introduced by air or by gas.
The low density of foam concrete, ranging from about 300 to 1600 kg/cubic meter, helps to reduce the dead load of the structure.
- High compressive strength of about 0.2 to 18 MPa.
- Ideal for thermal insulation, sound absorbance and fire resistance due to the textural surface and mono-structural cells.
- Alternatively known as low-density concrete or self-compacting concrete.
Raw Materials used in the manufacturing of Foam Concrete
Foam concrete is manufactured using cement, sand or fly ash, water, and a foaming agent. The foaming agent used can be natural or synthetic and include tannic extracts of the leather industry, sub soaped lye, and sulfite lye. Synthetic foaming agents can be prepared to have the properties required for the application, since the properties of natural foaming agents vary from time to time.
The fundamental components of Foam Concrete are water, binder, foaming agent, a suitable filler, additive, and fibre.
Water
Depending on the composition of the mixture, water content has to be adjusted. Lower water content leads to bursting of bubbles and a higher water content makes the mixture thin and causes bubbles to separate from the mixture.
Binder
Cement is commonly used as a binder: some of the varieties of cement in the binder content include ordinary Portland cement, rapid hardening Portland cement, calcium sulphoaluminate cement, and high-alumina.
Foaming agent
The density of the foam concrete is controlled by the foaming agent. Commonly used foaming agents are synthetic, protein-based, composite and synthetic.
Filler
Fillers improve the mechanical performance such as mix proportion design and long-term strength, and reduce costs. Some of them include silica fume, fly ash, limestone powder, fine sand, recycled glass powder, and granulated blast furnace slag.
Fibre
Fibres such as glass and polypropylene, red ramie, palm oil, steel, coconut, waste paper cellulose, and carbon enhance the strength of the foam concrete and reduce shrinkage.
Manufacturing Process of Foam Concrete
Foam concrete is a kind of soft, plastic concrete material that contains the foaming agent and aeration agent. The foam is generated entrapped in a gel layer which contains a large number of tiny air bubbles. It can strengthen the concrete structure when consolidating microscopic air voids into large voids by foaming.
Foam Concrete is prepared in 2 ways: the pre-foaming method and the mix-foaming method. Common mixers used in FC production are the inclined drum, pan mixer used for concrete, or mortar. Depending on the method of foam concrete production adopted, we choose the mixer type, mix proportion, and mixing order.
The two methods and their procedures can be summarised as:
- In the pre-foaming method, the foam and the base mixture are prepared separately and then mixed at a later stage.
- In the mix-foaming method, the foaming agents are mixed with the base mixture, to begin with. Cellular structures are produced by the foam in FC.
Bubbles are generated in the foam concrete in either of two ways: dry or wet process. In the dry process, more stable bubbles are produced, ranging in sizes less than 1 mm. In the wet process, bubbles of sizes from 2 mm to 5 mm are generated.
Quite often, the pre-foaming method is preferred to the mix-foaming method although the quality of foam concrete can be controlled in both these methods. The former has lower requirements for foaming agents and produces a stable foam. This helps to withstand the pressure of mortar until solidification. Hence the foam concrete’s pore structure is considered more reliable.
Applications of Namratech Foam Concrete Works in Coimbatore
Some of the applications of our foam concrete services in Coimbatore include:
To feature holes beneath buildings. To reduce the effect of water on underground constructions such as tunnels. It’s also particularly useful to help protect against aggressive water that may penetrate over time due to the foam’s extremely efficient barrier properties.
Whether you’re struggling to find an affordable alternative to installing heavy thrust bearing systems, need a reasonably-priced method to backfill beneath buildings and pipes or have an access problem in existing utility trenches, we have the solution for you.
Some of our specialities include:
- Sewers, Pipelines & Tanks
- Cellars and Basements
- Service Ducts and Shafts
- Sinkholes
- Culverts and Subways
- Bridge Abutments
- Embankments
- Tunnel Stabilisation
- Road Pavement Reinstatements
- Road fill
- Trench fill
- Tank fill
Our highly skilled teams are able to complete your project professionally, efficiently and accurately, on time, every time. Manufactured from industrial grade foam in our concrete foam manufacturing facility, our products have been proven engineering solutions for decades
Benefits of Namratech Foamed Concrete Service in Coimbatore
Globally, cement-based Foam Concrete is widely used for tunnel grouting and to facilitate tunnel drainage and is already in implementation in highway tunnels in some countries. Due to the excellent permeability, effective formation and distribution of open-cell foams, these implementations are largely successful. Our line of foam concrete solutions is perfect for a wide variety of applications, such as sewers and pipelines, culverts, subways, trenches and tanks. We’ll help you determine the application that’s right for your needs by providing precisely the right foam concrete for these spaces and more.
Namratech Foam Concrete Services has been helping both commercial and domestic customers in Coimbatore with all sorts of building projects for years now so you can be sure that we’ll be able to help you with any project you need help with.
Our foam concrete is a great lightweight concrete mix that helps save money on your construction or renovation project. Easier and less expensive to produce, transport and use, our foam concrete mix is made from quality materials and will help you tackle major tunnel lining repairs as well as enhance drainage in other structures. We have bulk deliveries for long-term storage and an expanding network of local distributors in Coimbatore.
Over the past years, Namratech Foam Concrete Services in Coimbatore has been carrying out foam concrete services for bulk filling, ditch repair, retaining wall, housing insulation, reinforcing foundation walls, sealing tunnels, and bridge abutment backfill, slab structure of the concrete floor, housing insulation, etc. It is also widely in demand as a nonstructure or semi structure member for underground engineering, commonly in applications such as grouting works for tunnels, damage treatment, and liner structures.
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