@sprunch I am driving from Anderson island was to indigo morning of July 31 to help prepare. Would be willing to give someone a ride it you are in Tacoma, Olympia area and need a ride. Will be leaving the 11.
@K2 You are completely right in your assesment. You also have to take into consideration that this is something that was built in Philippines. I guess they did not require engineering specs there and that it have been built like an accessory building. This is akin to the mini house movement, that is not allowed in many states because of regulations. I guess a real solution lies somewhere between this foamed celular concrete and a better reinforced version. This mix should have some sand, and be made with magnesium oxide concrete, which is stronger. I would also look for a better foamer that is more stable and last longer and reinforce with basalt rebar to avoid rust in the future. As I have said before, a sandwiched structure with the celular concrete in the middle, then an external layer of regular full strengh shotcrete and an internal layer of magnesium oxide cement would make for the ultimate structure. When I finish my test subjects I will send them to an engineering firm to do a proper compression and tensile strengh test and post some results. I have too many projects now but will definitely share when I finish mine. The ones they do use a fiber to reinforce the celular concrete,but still it would need a proper test to get to final numbers. I think this type of material is stronger than wood, but not stronger than regular concrete. Eventually I will have my answer and will share here.
You can use foamed concrete for insulation, but I'd be sure you have a structural engineer check the design of any load bearing foundation. You'll be ok with enough surface area and strong enough beams to transfer and spread all the forces over the foamed concrete, but you need to design this.
Joe is correct, you do not need an autoclave for foamed concrete. There are concrete blocks and other shapes that are available in autoclaved cellular concrete - they have higher strength than what is generally made using foamed concrete.
NO. You'll have very, very low strength. You need to use portland cement. You can and should use fly ash in your recipe (your mix design to concrete people). Fly ash is a polozan - the secret of the Roman Empire. That's why a lot of their buildings are still standing hundreds of years later.
Your mix design is critical for a lot of reasons. You need strength, you want low shrinkage, you don't want your concrete to constantly be shedding dust, you don't want the surface to pop loose, and a lot of other things. Get a good mix design before you start! Pay very close attention to water cement ratio! Too much water will ruin your mix. It is best to do a lot of reading about foamed concrete before you begin. You don't want to build a nice looking structure, only to watch it crumble over time.
I wouldn't use foamed concrete for a floor surface, as it is not strong enough to withstand the wear a floor gets. You don't want to have chair legs digging holes in your floor. I would suggest that if you poured a thick layer (15 cm or 6") of foamed concrete, then poured a 5 cm or 3" layer of 4000 psi concrete over the top, you'd have a good surface with insulation from the ground. I would not use foamed concrete in any load bearing portions of the floor! Your structure needs to be sitting on hi strength concrete or something that will hold the expected forces that the foundation will see during the life of the building. If your foundation is not strong enough, it will crack and shift, which will crack and shift the whole house.
The compressor is what actually makes the foam. The little dragon is just a water pump to take the soap and water solution to the inlet of the tube that mixes the water with compressor air to make foam. I think but have not tried it , that even a gravity feed system for the soap solution will also work if you can get a 5 gallon bucket high enough. Inside the tube there is steel wool mesh to act as a filter to better disperse the water/soap/air mixture. I have a carbonator pump bought at ebay for another purpose, but it works just fine to move a soap solution and have adjustable output. Some carbonator pumps can be get from 10-50 dollars at ebay. The size of the bubbles is very important so your pressure along with the type of steel wool filter you use will impact bubble size and consistency. Start by making a lot of cubic or cylinder samples and add different fibers and rebars. Try different proportions and them maybe send them out for compressive and tensile tests, and you will find the perfect ratio for whatever you are building. Magnesium oxide cement, if you can get it, makes for a thinner concrete with higher strengh, so you could actually use less to do more, but it is more expensive. There is a video on youtube of a guy that actually takes a little dragon apart and shows all the inner tubing, look for it. Since you are looking for an insulator, maybe you could use mineral wool, that comes under different trade names like rockwool, and incorporate it into the aircrete mix. It is made of basalt fibers which are volcanic mineral, so they are completely natural, wont rust, and you wont need to use styrofoam. Good luck in your testing.
Our new Green Dragon isn't available yet. We're in the process of upgrading it, but not sure when the it will be available.
The Little Dragon is available and you will need Little Dragon to feed foam to the upgraded Green Dragon.
Little Dragon is our stand along continuous foam generator designed to feed foam into our foam injection AirCrete batch mixer and our new Green Dragon. Little Dragon has a built-in air pressure regulator with a dial indicator that makes it very easy to adjust and monitor. It’s easy to produce consistent foam of the proper density to make good quality AirCrete.
Little Dragon can be use to batch mix AirCrete with our foam-injection mixer or a drill attached to a mixing paddle. Batch mixing means mixing the exact quantity of ingredients together in a barrel one batch at a time.
Batch mixing is the preferred method for small projects. It gives a precision mixture every time.
I think that a certification for each state would not be available because every state and county have their own regulations, and they change differently. You should contact an engineering firm local to the area you want to build and ask them how can you make the aircrete building to comply with the area you are going to build. Even a regular wood house that may be legal in one state or country, could be ilegal in another, so you have to ask this locally to your county or state requirements. You can even build some of the blocks and take them to an engineering firm to test them and give you the tensile and compressive strengh. It is better to get your local code and build around their minimum requirements than trying to convince them to accept your design.