Design of houses from fiber foam concrete. Comparison of materials: aerated concrete blocks and fiber foam concrete How to build a house from fiber foam concrete

Blocks based on foam concrete with the inclusion of fiber have become very popular with modern builders. This is due to the fact that this material has a number of positive qualities, which are so necessary for the walls of the house. However, it is worth remembering that fiber foam concrete is a product made of sand, cement and fiber-based foam, which means that it also has its drawbacks associated with the production technology and the components used.

Properties and scope

To begin with, it must be said that the materials of this type are made certain companies. Therefore, it is worth talking about product quality based on general characteristics rather than based on a specific batch. Given this, we will consider fiber foam concrete as a separate product created without violating the technical process ().

Characteristics

First of all, it is worth saying that this type of material can be safely called the most environmentally friendly. It is assigned index 2, while wood is in first place, and brick is in tenth ().

At the same time, fiber foam concrete does not need additional processing, which would reduce this indicator, which cannot be said about wood, which needs impregnation and fire protection.

• Special attention should be paid to the fact that products made from this material may have various dimensions. Large blocks are especially in demand, as they significantly reduce installation time and simplify it. Also, in their manufacture, you can take into account some features in advance and create additional forms, which will completely eliminate diamond drilling holes in concrete or minimize their number.
• It must be said that this material retains heat well, but it should not be used without additional insulation. The fact is that fiber foam concrete blocks do not have a homogeneous structure, since air bubbles in them are arranged randomly and have different size. It is because of this that it is worth installing at least a thin insulation so that the insulation is uniform, although this may not be done in regions with a warm climate.

• Properly made foam fiber concrete has excellent antibacterial performance.. He is not afraid of mold or fungus, but professional craftsmen still advise adding a primer with similar additives to the solution or performing subsequent processing.
• Usually, the disadvantages of fiber foam concrete are not as pronounced as the advantages. They are relatively low strength. Moreover, this material is quite suitable even for the manufacture of three-story houses.
• It is also worth mentioning that these blocks are very easy to process.. By choosing them to create walls, you can avoid such a process as cutting reinforced concrete with diamond wheels.

Advice! When purchasing a batch of such material, you should ask the seller or manufacturer for a quality certificate. It must describe all the declared characteristics and their compliance.

Application area

Given that such blocks are light in weight, they are often used to make interior partitions or jumpers.

• Many craftsmen use this material to create small buildings and houses. The fact is that its price and properties make it possible to save money and solve a number of problems associated with insulation and environmental cleanliness.

• It is not recommended to use such blocks for the manufacture of a foundation or a plinth. Usually the installation instructions suggest using stronger products in such cases.

Advice! Do not confuse this type of material with aerated concrete, since they have completely different characteristics, which naturally determines their scope.

• When doing work with your own hands, it is worth remembering that these blocks have a certain absorbency, and therefore the solution is made slightly liquid.
• It is worth remembering that each manufacturer of these materials has its own system of standards, which does not always coincide with popular dimensions. Therefore, when ordering blocks, you need to know in advance about their size.
• Do not leave finished products made of such material without an appropriate finish. She not only decorates appearance, but also serve additional protection.

Conclusion

After reviewing the video in this article, you can learn more about this type of building material. Also, based on the text above, it is worth concluding that for small buildings, such blocks are the most optimal and can be completely used without insulation ().

However, it must be remembered that fiber foam concrete does not have a very good appearance and needs to be additional finishing. At the same time, his specifications save a lot of money, which is quite justified.

Fiber foam concrete blocks are popular in the construction world. This is due to a number of advantages of this material. But you still can’t do without minuses, monolithic fiber foam concrete, due to its components, is a fragile material, which means that its production technology is different and requires increased effort. With the correct mixing of the components, in compliance with the proportions and technological process, the material will be strong and reliable.

Areas of use

The use of fiber foam concrete blocks is relevant in the installation of partitions between rooms of houses due to its light weight. As well as:

Advantages

The advantages of fiber foam concrete far outweigh its disadvantages. Benefits include:

Due to its warmth, lightness and strength, fiber foam concrete is better than standard foam concrete.

Flaws

The disadvantages of foam concrete blocks using fiber include: low fracture strength and fragility in fiber foam concrete. As well as low productivity in the construction of houses and buildings with more than three floors. Non-standard dimensions of finished blocks.

Equipment for the production of

Cutting equipment for the production of blocks.

Used for the production of fiber foam concrete block:

• mobile complexes for pouring;
• mixers for the production of fiber foam concrete, which are designed for the preparation of porous mortars density from 200 kg/m.;
• small-sized mobile units, which produce up to 5 m of building material per shift.

Before you start working with blocks based on foam concrete with the addition of fibers, you need to read the recommendations experienced builders. When doing work with your own hands, you need to remember that there are components in the blocks that are highly absorbent. This suggests that the solution must be prepared in a liquid consistency.

It is recommended that products from blocks based on fiber foam concrete not be left without an appropriate finish. After all, they can both decorate the appearance and serve as additional protection. When working with fiber foam concrete, it is important not to forget about the system of standards that is inherent in each manufacturer. Therefore, when ordering blocks, you need to clarify their dimensions in advance. The packaging of the goods must not contain damage, and the complete set must correspond to the order.

Blocks based on foam concrete with the inclusion of fibers are advised to be fixed with nails and dowels with an anti-corrosion coating for small loads, as well as special dowels that are recommended by the manufacturer of fasteners for a cellular block at high loads.

But they have one weakness: Wall shrinkage or increased defrosting cycles may cause cracks in the material. Fiber foam concrete successfully eliminates these problems.

How did fiber foam concrete appear

The structure of the word itself shows that at first there was foam concrete: a foamed mixture of cement, sand and water. Foamy structure of the crude mixture was given by natural or synthetic foaming agents. Having cut the resulting mass into blocks, without the use of high-tech equipment, the molded mixture was allowed to harden directly on outdoors. To increase the strength of the block, an autoclave was used, but such hardening was enough, at most, for the construction of a two-story house.

The idea of ​​strengthening the strength of the foam block to plastic deformation, stretching and bending formed the basis for the creation of a new generation of foam blocks - reinforced with polypropylene fiber.

Reinforcement of foam blocks

To give the porous structure of the material a greater internal conjugation, due to the uniform introduction of dispersed reinforcement (0.5-2%) into the composition of the mixture use different types fibers or granules:

• synthetic;
• steel;
• glass;
• basalt;
• composite;
• vegetable.

At the same time, the desired properties of the block can be set using reinforcing fibers coated with surfactants ( optimal diameter fibers - 18 microns) in the form various combinations, combinations, new proportions. The fibers are evenly distributed over the entire volume of the mixture in all directions, creating an internal cohesion of the concrete, which prevents hidden defects in the future.

fiber quality it is easy to determine by the edges of the block: it should not stick out, but softly and elastically be included in the concrete structure. To make sure the quality of the product, you should ask the seller for a certificate for fiber: glass fiber is cheaper, tougher and more vulnerable to alkali. The best option- polypropylene.

The creation of a new generation material - nanofiber concrete is based on the use of extended cylindrical structures as reinforcing fibers, having a molecular structure and D from 1 to several nanometers, the so-called "nanotubes".

What gives the reinforcement of foam blocks

1. Flexural tensile strength is 25% higher.
2. Shock resistance - 9 times higher.
3. Increase in density as the ratio of mass to volume - up to 1,200.
4. Thermal insulation qualities - 30% higher.
5. Blockage of capillaries reduces water permeability.
6. Increases fire resistance, allowing the destruction of the object of reinforced blocks only after 14 hours.
7. Frost resistance increases - 1.5 times (up to 100 cycles).
8. Increased sound insulation performance.
9. Increased strength to local loads expands the scope of fiber foam blocks, including multi-storey construction.
10. The increased strength of the blocks makes it possible to reduce their dimensions and, thereby, reduce the cost of transportation (28 blocks or 56 semi-blocks in 1 cubic meter).

Technical characteristics of fiber foam concrete blocks

They are not very significantly different from the main characteristics of the foam block:

• density, which is reflected in the marking: from D300 to D1200;
• concrete class in terms of compression (B and M);
• frost resistance (at least 50 cycles);
• thermal conductivity coefficient (from 0.13 W/mºС to 0.38 W/mºС);
• drying shrinkage (no more than 0.7 mm/m);
• block weight - 13-27 kg;
• dimensions: 20x30x60 and 10x30x60.

Similarity to foam block

1. Both types of building blocks have the same production technology, which is regulated by the same GOST 21529-89.
2. Do not require serious investments in the production process.
3. They are made by molding and cutting the raw mass (for fiber foam block, cutting is less effective, since fiber loses 20% of its strength when sawn).
4. Both types are characterized by lightness, durability.
5. They are fire resistant.
6. Good at retaining heat in the room.
7. They are flexible with machining cutter, puncher, shtrober.
8. For masonry work of both types of material, special glue is used.
9. Have general application in accordance with the density index:

• for thermal insulation of internal walls;
• to create load-bearing structures;
• for structural and thermal insulation works.

Have identical in appearance and purpose masonry units:

• wall blocks;
• partition walls (semi-blocks).

Non-standard products (of the required density and dimensions) are produced under the customer's order.

Where is it preferable to use fiber foam block

• Construction industrial buildings, garages and household buildings;
• construction low-rise buildings frameless way;
• construction of mansards, dachas, cottages;
• during the reconstruction of buildings;
• for the device of inter-apartment and inter-room partitions;
• for lintels over window and door openings;
• for the device of formwork of a monolithic belt;
• for transverse ligation of masonry;
• construction of buildings of any number of storeys on a reinforced concrete frame.

Advantages of fiber foam concrete acquired by it in the process of reinforcement

1. The fiber frame distributes the load throughout the volume of the wall blocks.
2. Due to the ideal geometry of the blocks, even walls can be erected.
3. Has resistance to high humidity. Does not get wet even when in contact with water.
4. Allows the installation of communications (pipes, electrical networks), both open and hidden.
5. Holds fastening to the wall of heavy objects (pictures, cabinets, shelves) well.
6. Fiber foam block is applicable for the construction of three-story houses without a reinforcement belt.
7. Allows you to reduce the thickness of the walls (in comparison with brick) by 3 times.
8. Reduces costs for Construction Materials 4 times.

The production enterprise LLC "BAZA SM" produces products from non-autoclaved fiber foam concrete in accordance with TU 5741-001-80392712-2013 (Certificate of Conformity No. ROSS RU.AG75.N05997 dated 11.10.2013).

At a small specific gravity(an average of 3 times less brick) fiber foam concrete has strength sufficient for the construction of cottages with bearing walls up to 3 floors.

Has good heat and soundproof properties. 200mm of fiber foam concrete with a density of 600 kg / m 3 is equivalent in terms of heat and sound insulation to approximately 1000mm brickwork. In houses built of fiber foam concrete, it is not cold in winter and not hot in summer.

Fiber foam concrete is a fire-resistant material, as evidenced by a fire certificate and tests for fire resistance of wall structures (Fire certificate for products made of fiber foam concrete No. NSOPB.RU.PR014.N.00091 dated 19.03.2014).

Fiber foam concrete is easily sawn with a hacksaw. AT construction stores a hacksaw for foam concrete with victorious soldering is offered.

Due to the introduction of fibers into the composition of foam concrete, a more closed pore structure is formed, heat-insulating, sound-proofing and other characteristics are improved:
• fiber foam concrete is less sensitive to moisture,
• in terms of frost resistance, fiber foam concrete is several times superior to most of the existing wall materials, increases the durability of the material,
• impact strength increases, brittleness decreases, it becomes possible to transport the material over any distance by any means of transport,
• increases the tensile strength of the material in bending, which makes it possible to manufacture products of complex configuration,
• increases significantly resistivity pulling out screws.

FIBERFOAM CONCRETE is a type of concrete, which means RELIABILITY and DURABILITY.

Physical and mechanical properties of fiber foam concrete
Type of fiber foam concrete	Density, kg / m 3	Class by strength for compression	Frost resistance grade, cycles	Vapor permeability, mg/(m h Pa)	Thermal conductivity, W/m °C
					dry	for operating conditions "A"
heat insulating
		B1; B0.75; B0.5
Structural and heat-insulating		B1.5; B1 ;B0.75
		B5; B3.5; B2.5; B2

Table of energy efficiency of fiber foam concrete and aerated concrete

	Name of indicator	Aerated concrete D500	Fiber foam concreteD500	Note
		GOST 31359-2007	TU 5741-001-80392712-2013
	The coefficient of thermal conductivity of the material in a dry state, W / m ° C			The index of fiber foam concrete is better by 30%
	Coefficient of thermal conductivity of the material under conditions "A"*, W/m °C
	Thermal conductivity coefficient at equilibrium weight moisture W = 4%**, W/(m °C)

Note:
* - Operating conditions are determined in accordance with the requirements of SP 131.13330.2012 "Construction climatology". Operating conditions "A" correspond to climatic conditions Rostov-on-Don, Krasnodar, Astrakhan, Volgograd, Voronezh, Belgorod, etc.
** - data according to table A.1 of GOST 31359-2007 "AUTOCLAVE CELLULAR CONCRETE"

Comparative characteristics of fiber foam concrete

Comparison of wall structures with equivalent heat transfer resistance
of the most common fireproof wall materials.

Indicators	Wall of ceramic brick(voidness-13%, density 1600 kg / m 3	ceramic wall solid brick(density 1800 kg / m 3) with insulation	Fixed formwork from expanded polystyrene and reinforced concrete with a density of 2500 kg / m 3	Wall made of aerated concrete blocks with a density D500 kg/m 3	Wall made of fiber foam-concrete blocks of BAZA SM LLC with a density of D500 kg / m 3
Wall thickness, m	1,29	0,46	0,25	0,40	0,30
The coefficient of thermal conductivity of wall materials in conditions "A", W / m ° C	0,58*	0,041 / 0,7*	0,041 / 1,92*	0,141**	0,111***
Frost resistance of the outer wall material, cycles	35	35	--	35	75
Weight 1m 2 walls, kg	2370	800	375	270	200
The cost of 1 m 2 of the wall, taking into account materials and work on the construction of the wall, rub.	5990****	1970****	2025	1850	1600

* - data according to SP 23-101-2004 "Design of thermal protection of buildings"
** - data according to GOST 31359-2007 "AUTOCLAVE CELLULAR CONCRETE"
*** - data according to TU 5741-001-80392712-2013 "NON-AUTOCLAVED FIBERFOAM CONCRETE PRODUCTS"
**** - the cost of 1 m 2 of a ceramic brick wall is calculated based on the condition of using only backing bricks

Fiber foam concrete blocks (FPB) are by far the most effective material for outside walls. The main advantage of fiber foam concrete is its low thermal conductivity, which allows you to switch to 2-layer external walls (brick + block). In addition, it is lighter than wood, a good sound insulator and is not combustible, since it is a stone product.
ALF-B line for the production of fiber foam concrete blocks

The main advantage of using blocks in construction is the reduction of construction time. blocks are gaining strength in production. Manufacturing in the factory allows you to achieve High Quality and constancy of block properties. Not least important is the fact that small-piece technology allows you to build buildings with a free layout and a variety of architecture.
The advanced equipment of "Sarmat Group" for the production of fiber foam concrete blocks allows you to refuse from pouring into molds, and cut on saw machines with an accuracy of 1-2 mm, providing the necessary roughness and the absence of traces of lubrication. The dimensions of the blocks are adjusted on the machines of the complex in accordance with GOST 21520-89.
The use of automation and high-precision dispensers by Fokon makes it possible to reduce the cost, ensure high and stable quality of the blocks, excluding the "human factor". The control unit makes it possible to remotely diagnose the line and receive operational information for the warehouse and accounting, which reduces inventory as source materials and finished products.
Line operation description: The FPB line is designed for the production of non-autoclaved fiber foam concrete based on mineral binders and aggregates, a foaming agent and water. To make the material more high performance quality, polyamide, polypropylene or basalt fiber is used.
The mixture is prepared in separate room– Mix preparation module (Fig.1). The manufacturing process of the FPB mixture takes place in automatic mode.

Rice. 1 The Module contains a control unit for the preparation of a mixture of BUSm, which controls the process of obtaining fiber-reinforced concrete, and can also store recipes, display the status of the main units of the Module and prepare information for accounting. The process of transport and loading of components occurs automatically. The capacity of the bunkers is designed for 3-6 hours of operation. The module is serviced by 1 worker-operator. Further, the mixture from the Module is fed to the position of pouring the array (into the mold), here the 2nd worker is located. The pouring position is the docking point of the Pouring Module with the automated sawing complex (ASC) through the ready button.
The poured mass moves on a trolley into a chamber with different temperature zones. The chamber is made in the form of a "loop" in which trolleys move along the rails. After 5-8 hours, the finished array is at the cutting position of the agro-industrial complex.
Photo of the saw complex in Dubna On the agro-industrial complex, allowances are cut with saws from all sides and a given block size is obtained. Finished blocks automatically stacked on a pallet 1200x1000. APC controls 1 worker-operator. A fourth worker sets up the pallets and packs the products. Loader driver - 5th worker.
The duties of the master technologist include quality control of FPB blocks at all stages, selection of the necessary recipes, equipment washing control, etc. He also monitors the operation of the complex as a whole, the supply of materials and finished products solves current issues of repair and prevention. Note:

• Waste disposal and block palletizing systems are available as separate options.
• To reduce storage costs, it is recommended to additionally install a “finishing dryer” line, after which the blocks can be immediately (after 24-30 hours) sent to the customer.

The produced FPB lines are designed according to modular principle, their performance can be set depending on the needs of the market in each case. The lines are designed for continuous work in 3 shifts. Line payback from 13 months.
On the floor of a house with an area of ​​600 m2, an average of 70 m3 of blocks for external walls and more than 100 m3 for internal ones will be required. for a 17-storey 1 entrance building up to 3000 m3 blocks.
An example of technical and economic calculations for a line with a capacity of 3000 cubic meters. meters of blocks per month can be downloaded on this page (on the right).