1

M/S T.S.K. ENTERPRISES

CONTRACTOR
Specialist in: Foam Concrete, Insulation, Waterproofing, Pest-
Control, Ups Sale/Service & Civil Works.
D-5/324, Sangam Vihar New Delhi-110062
Email: tskenterprises@gmail.com
Mob: 9810785395
Pan: CNSPS4673J
GST No: - 07CNSPS4673J1Z2

Ref No: ___ Dated:_________

Introduction of foam concrete

Foam concrete, also called cellular light weight concrete is produced by the mixing of
cement, sand, 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 aluminium 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 0.3 to 25.00 N/mm2
and 320 to 1800 kg/m3. The plastic density of the material is about 150 to 200 kg/m3
higher than its dry density.

USES:
1. Foamed light weight concrete in the form of bricks, blocks or poured in-situ is used for
thermal insulation over flat roofs or for cold storage walls or as non-load bearing walls in
RCC/Steel framed buildings or for load bearing walls for low-rise buildings.
2. Fire rating of foamed concrete is far superior to that of brick work or dense concrete.
3. Bulk filling, using relatively low strength material, for redundant sewerage pipes,
wells, disused cellars and basements, storage tanks, tunnels and subways etc.
4. Infill to the spandrel walls of arch bridges.
5. Backfill to retaining walls and bridge abutment.
1
2

6. Stabilizing soil, for example in the construction of embankment slopes.

7. Grouting for tunnel work.

BATCHING AND MIXING:

The dry ingredients like cement & sand shall be fed into the mixer first and thoroughly
mixed to ensure even distribution of cement. The appropriate amount of water shall be
added thereafter continuing the mixing. The preformed foam, which is made by blending
the foam concentrate, water and compressed air in predetermine proportion in a foam
generator, calibrated for a specific discharge rate, shall be added in measured amount to
the slurry of cement, sand and water in the batch mixer. After an additional mixing to get
uniform consistency, the slurry form of foamed cellular concrete of desired wet unit
weight shall be ready to be poured out into forms/moulds etc. When truck mixing
equipment is used for foamed concrete, the preformed foam shall be added at the job site
just prior to pumping or otherwise conveying the concrete into forms.

The building blocks may be de-moulded after 24 hours from pouring of foamed concrete.
Curing shall be done s per IS: 456-2000. To speed up the production, the blocks shall be
cured by saturated steam at an average temperature of 460C ± 150C for a period of 24
hours or more to attained the required strength. After curing, the blocks shall be allowed
to dry under shade for a period 2 to 3 weeks, so as to complete their initial shrinkage
before being used in the work.

RECOMMENDED USAGE OF FOAM CONCRETE DENSITY

Density 320-600 kg/m³:

This density is primarily applied for thermal insulation or fire protection. It uses cement, fine sand,
water and foam and can easily be pumped. Foam generators allow the production of stiff foam for
slopes to be applied on roof-tops.

Density 700-800 kg/m³:

Is also used for void-filling, such as an landscaping (above underground construction), to fill voids
behind archways and refurbishing of damaged sewerage systems. It is also been used to
produce building blocks.

Density 900-1100 kg/m³:

Serves to fore mostly produce blocks and other non-load bearing building elements such as
balcony railings, partitions, parapets and fence walls etc.

Density 1200-1400 kg/m³:

Are the most commonly densities for prefab and cast in situ walls, load-bearing and non-load-
bearing. It is also successfully used for floor screeds (sound and insulation plus weight reduction).

2
3

Density 1600-1800 kg/m³:

Would be recommended for slabs and other load-bearing building elements where higher
strength is obligatory.

FOAM CONCRETE MIX DESIGN*-

Dry OPC 53 Fine Sand Water Foaming Water

Density Grade Kg Liter’s Agent Ltr Liter’s
Per M3 Cement Per m3
Kg
320 300 20 120 1 16
400 300 100 140 1 16
500 300 200 160 1 16
600 300 300 180 1 16
700 350 350 200 1 14
800 350 450 220 1 14
900 350 550 240 1 14
1000 400 600 260 0.750 14
1100 400 700 280 0.750 12
1200 400 800 300 0.750 12
1300 450 850 320 0.750 12
1400 450 950 340 0.500 10
1500 450 1050 360 0.500 10
1600 500 1100 380 0.500 8
1700 500 1200 400 0.500 8
1800 500 1300 420 0.500 8

FOAM CONCRETE COMPRESSIVE STRENGHT, THERMAL

CONDUCTIVITY & WATER ABSORPTION.*

Dry Density Per Compressive Thermal Water

M3 Strength Conductivity Absorption %
N/mm2 W/m.k.
320 0.3 0.076 15.5
400 0.4 0.098 15.5
500 0.5 0.110 15.0
600 1.0 0.134 15.0

3
4

700 1.5 0.151 15.0

800 2.5 0.174 12.5
900 3.0 0.204 12.5
1000 3.5 0.238 12.5
1100 4.5 0.267 11.5
1200 6.5 0.314 11.5
1300 8.5 ……… 10.0
1400 12.0 ……… 10.0
1500 14.5 ……… 10.0
1600 17.5 ……… 7.5
1700 20.5 ……… 7.5
1800 25.0 ……… 7.5

METHOD OF CONSTRUCTION:

1. Apply waterproofing treatment layers over the R.C.C. Slab

uniformly.
2. Laying foam concrete over the waterproofing layers. Thickness of
foam concrete should be minimum 75 mm to 250mm thick
depending upon the slope required to drain the rain water.

SPECIAL INSTRUCTION:

1. After 24 Hours of laying foam concrete is cured by sprinkling of

water over it or to placing wet Hessian bags over the surface.
Workman would not be allowed to move over its surface before 7
days of its casting.
2. Before flooring 25mm thick screed concrete (1:2:4) over it surface
will be better where movements are more.
3. Where waterproofing its required after 5 days of casting of foam
concrete water proof plaster should be applied on its surface.
Thickness of plaster should not be less than 20mm. Of Mix (1:3).
Then after 24 Hours, Plastered surface is cured for 7 days.
4. Over the plastered surface tiles are laid and grouted with cement
mortar and finally tepid.

4
5

Note:-
The contractor reserves the right so added. Amend and vary without
prior notice, the specification mentioned above.

For M/s T.S.K.ENTERPRISES.

Proprietor