Cellular concrete in construction

Lightweight cellular (foamed) concrete is made by mixing pre-formed stable foam and cement-based slurry. Cellular concrete is replacing traditional materials in the construction industry due to its lightweight, high quality and availability.

Cellular concrete can have a range of dry densities, typically from 400 kg/m3 to 1600 kg/m3 and a range of compressive strengths, 1 N/mm2 to 15 N/mm2. It is very versatile, since it can be tailored for optimum performance and minimum cost by choice of a suitable mix design

The cellular concrete market is projected to grow from USD 337.6 Million in 2015 to reach USD 449.8 Million by 2020, at an estimated CAGR of 5.9%.

Accelerated urbanisation, growth in infrastructural activities, and increasing industrialisation have driven the growth of the cellular concrete market. The increasing income and spending capacity of people in developing economies and increasing demand by end-use sectors such as commercial buildings, residential buildings, and infrastructure are the major factors driving the market.

This growth will be stimulated by expanding applications in construction components, blocks, void filling, and roof insulation.

In the UK the use of cellular concrete became popular after it was specified for trench reinstatement in the New Roads and Streetworks Act 1991. Other applications include road sub-bases, ground stabilisation, bridge abutments and strengthening, and land reclamation.

Due to its lightweight nature cellular concrete can indirectly reduce costs on a project by, for example, reducing the overall loading on a building so that fewer piles are needed to support it.

Cellular concrete is a very flowable material and so can be easily installed by using gravity and can be self-levelling. It is typically used to construct floor slabs, window panels and roofs.

The key companies involved in the market are:

• Propump Engineering (United Kingdom)
• Saint Gobain (France),
• Fillcrete (South Africa),
• Xella Group (Germany),
• Cellucrete (U.S.),
• Cematrix (Canada),
• Litebuilt (Australia),
• Nublok (South Africa),
• Laston Italiana S.P.A (Italy),
• Cellular Concrete Technologies (U.S.),
• Aerix Industries (U.S.),
• ACICO (Kuwait),
• Shirke (India),
• Broco Industries (Indonesia),
• Aircrete Europe (Netherlands).
• EAB Associates (United Kingdom)

Cellular concrete provides structure, insulation, and fire and mold-resistance. Cellular concrete products include blocks, wall panels, floor and roof panels, and lintels. It also provides a low-density fill material used in geotechnical applications.

The infrastructure sector accounts for the largest market share of the market and this trend is projected to continue during the forecast period. This segment is also expected to grow at the fastest rate during the forecast period. The increase in development in the construction industry and eco- friendly building material is expected to boost the growth of the infrastructure sector. The residential sector is forecast to be the second-largest segment in the market in the coming years.

The rising demand for lightweight building materials across the world is expected to drive the market. The road sub-bases segment will see the highest CAGR from 2015 to 2020, followed by building materials and concrete pipes.

The European region is expected to account for the largest share in the cellular concrete market from 2015 to 2020. Asia-Pacific is projected to be the fastest-growing region for the market during the forecast period. Countries such as China and India are transforming their economies from being agriculture-based to manufacturing and other industry-based economies. Increasing urbanised population in China and India and growth in disposable income are driving the cellular concrete market in Asia-Pacific.

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Comments

Cellular concrete, also known as aerated concrete or foamed concrete, is a lightweight building material used in construction for various applications. It is produced by introducing air or gas bubbles into a cementitious mixture, resulting in a cellular structure with a low density and high insulation properties. Cellular concrete offers several advantages that make it suitable for different construction projects:

1. Lightweight: Cellular concrete has a significantly lower density compared to traditional concrete, making it lightweight and easier to handle during construction. This characteristic reduces the overall dead load on structures and can be particularly beneficial for projects with weight restrictions.

2. Thermal Insulation: The air-filled cells in cellular concrete provide excellent thermal insulation properties, helping to regulate indoor temperatures and reduce the energy required for heating and cooling. This makes it suitable for building walls, floors, and roofs in both residential and commercial construction.

3. Acoustic Insulation: The cellular structure of the concrete also contributes to good acoustic insulation, reducing sound transmission through walls and floors.

4. Fire Resistance: Cellular concrete has inherent fire-resistant properties due to the presence of non-combustible materials, making it a suitable choice for fire-rated walls and other fire-resistant construction applications.

5. Workability: Cellular concrete can be easily molded and cast into various shapes and sizes, allowing for versatility in design and construction.

6. Reduced Shrinkage: The lower water content and the presence of air voids in cellular concrete result in reduced shrinkage during curing, leading to less cracking and better long-term performance.

7. Environmental Benefits: Cellular concrete often includes recycled materials, and its lightweight nature reduces transportation-related energy consumption during construction.

Cellular concrete is commonly used in various construction applications, including:

- Wall construction: Cellular concrete blocks or panels can be used to build walls in both load-bearing and non-load-bearing applications.
- Roof insulation: It can be used as an insulating layer on roofs to improve thermal performance.
- Floor insulation: Cellular concrete is used as a lightweight fill material for floor slabs, providing thermal and acoustic insulation.
- Void filling: It can be used for filling voids and backfilling applications due to its lightweight and flowable properties.

It's essential to follow the manufacturer's guidelines and consult with experienced professionals when using cellular concrete in construction to ensure proper mixing, handling, and installation for the specific project requirements.