AirCrete

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  Making aircrete to meet code...
  • Ignacio- DHOME  

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  Right now we are experimenting with laying out the rebar cage concept, and developing the block mould/form to be on the rebar cage. Since the blocks are made from a liquid, it can be poured into the rig, and then the thing unlatched and moved to the next station. Problem probably keeping the crete trapped in the form as it goes more horizontal. I am uncertain of how fresh poured aircrete will bond to existing dried aircrete. The other variable, is what exactly a municipal dept. requires of an engineered aircrete dome system like the monolithic. Once the code is cracked and one engineer stamps a plan and it is approved by some muniicipal fiefdom somewhere, it can be replicated. Open source sharing of knowledge and skills & kith/kindred is the key to liberating the serf from the oligarchs. Eventually the concept will bear fruit, and an Engineer will tackle it. I know of one, but it has to be done and proved first. One of these structures will need to be run through some software like ANSYS and destructive tested. https://www.ijirset.com/upload/2017/may/156_Numerical.pdf Basalt rods are the desired structural reinf material, but steel rebar is easy to score in any metroplex or lumber store. So far ive tinkered with holes in blocks and threading the blocks on the bars. Misery. not worth the effort. Works on a flat plane, but that radial dome curve is "special". The genius of the dome and aircrete is that it doesnt need all the engineering and reinf. bars as the laminated crete between fabric is the key.
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  Collapsing forms remedy- warm water
  • Ignacio- DHOME  

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  @Carolebrdn yes! Try using hot water in the foam mix. This is what we did at the Pt Townsend workshop and it seemed to have success. They had trouble later keeping the water warm, so I think they got an electric water heater like the link below to keep the foam mix warm. You could also keep the foam mix circulating by using the little dragon without any air on and just putting the outlet of the pump back into the top of the barrel. This circulation generates some heat in the foam mix from friction in the movement. Farm Innovators Model H-419 Ice Chaser Cast Aluminum Submergible Tank De-Icer, 1,500-Watt https://www.amazon.com/dp/B000HHO9LC/ref=cm_sw_r_cp_apa_i_DXbZDbTD8S5Q6
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  Big island sand source
  • vitusthemad  

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  Help!
  • daniellefiroozi  

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  @Ignacio-DHOME thanks Ignacio!
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  Drexel FM 160
  • Homer  

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  @anthonydjones thanks, try to contact them next week
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  pouring floor: in sections? Dry sticking to wet?
  • Traveler004  

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  Traveler, I too have been mixing in a 50gal drum with the hand mixer and found it a lot of work for my 67year old body. What I found was that, for me, the hardest part was getting a thorough mixing of the cement and water only, to be the most demanding. It was hard to get all the cement mixed into the 'slurry', with no or little residue/paste on the bottom of the barrel after I poured it out. (especially since I was doing this myself) What I was thinking, was that mixing the cement in a barrel mixer, assuring that it was well mixed, then pouring that slurry into my 50-gallon drum and adding the foam at that point. I'm new to this and have only done a few test batches, but my first test batches raised concerns with me since in the future I want to add sand 1:1 for a slab and can only imagine it getting more difficult. I guess the next best thing would be to find a 'younger' helper :-) Your thoughts would be welcome. Aloha, Jim
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  Autoclaved vs non-Autoclaved
  • Traveler004  

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  Foamcrete walls anyone?
  • noni  

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  @little-pig-store Fiberglass mesh looks amazing. But the cost here would be 10 bucks for a 2x3 foot panel :( But I know cement sticks to glass just like rock. where it doesn't stick to organic materials like wood and it doesn't stick to plastic so i'm not sure why polyester material is working for people. I have not tried it. I'm trying to use pink fiberglass bats because i have them. So far it sticks but i've not found a way to mix it in. I just gums up my mixer. Have you looked into or tried calcium aluminate cement?
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  Basement aircrete application? Metal stud walls
  • scottwojo  

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  no mesh. Watch this guy to get an idea of what i'm doing. https://www.youtube.com/watch?v=ddedMmuj7xY Its basically this but lego up the wall. the peice of rebar at the top block is secured to the joist with a steal fastener.
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  Aircrete safety
  • Traveler004  

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  @Ignacio-DHOME Good idea. You have to contend with the particals thou. perhaps wetting it and then shopvac. I'm just thinking it might be better to hepa vacume it up as dust. Wetting it might make it harder. would have someone stand next to me and vacume as i saw. I don't know but it's a discussion no one seems to be having. I know it's not the fun part, but still important. I saw a photo of someone who knelt on his wet slab (trying to screek it) and didn't wash it off and ended up in the hospital for weeks with burns down to the bone. So it's not like it's nothing. I always were a mask but after its cut it falls to the ground where it can easily be kicked back up. I mean the particals don't disappear after i'm finished cutting. I have designated a "toxic" area on my property where we don't plant and animals aren't allowed so I have a place to clean tools and buckets etc, the making and cutting is done is habitable areas.
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  Foamcrete walls anyone
  • noni  

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  @Ignacio-DHOME Hi Ignacio sure, I can take photos but I don’t know how to post them to the forum. Instructions gratefully received. Cheers Noni
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  Q about interior polycloth layer
  • upwinger  

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  @upwinger yes. Glass is much stronger.
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  Aircrete casting
  aircrete sculpture casting • • daniellefiroozi  

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  @daniellefiroozi sorry. no idea.
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  How much foaming agent?
  • LibbyL  

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  @LibbyL more water per soap makes it heavier. The more foam, the lighter the mix... Common sence right? Am I missing something?
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  Can this dome handle.heavy snow loads, much summer rain? Wet part of Idaho. No one.there in winter to take snow off.roof, walls. Will this work?
  • fargoshandmaiden  

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  And thanks again That is.encouraging that it would.work.
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  Pools with aircrete
  • thoughtdrops  

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  I think a pool liner would work well, but not sure if the polyclothe mortar layer is enough to hold the aircrete together when the pool is full of water.... that's an enormous amount of weight and pressure. I just purchsed a home and will be moving soon. There is a jacuzzi in the backyard that I think I will insulate around the bottom with aircrete by spraying it in with a texture gun. That wont be for support, only for insulating.
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  Prep blocks for electric, etc.
  electrical plumbing • • ormom8  

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  @ormom8 Yes! Aircrete presents us with new paradigms of creativity. You could just tack your wiring up to the inside of the walls and finish with the earthen or "other" finish. Then if you need to change it just scratch them out. They would only be an inch or so deep. and re-plaster. The conduit would provide some protection from something banging into the walls and shorting out a wire. I encourage everyone to NOT create new "Aircrete rules boxes". Live creatively and outside the "boxes"
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  Aircrete pour in place pitched roof?
  • naeveh1  

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  @naeveh1 I don't see why not. Being that it's lightweight it could work great. Make sure to use the poly fiber on the inside of the pour to hold it all together monolythically. Also, will give you an insulative ceiling...FYI: You may not be able to walk on it though. Also, how do you expect to mix and pour this? Look in to a plaster mixer if necessary....this may be a good alternative to hand mixing. Too bad you did'nt use this for your walls. You would have insulative walls by now and a finished surface to paint.
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  Can I go up to a 40' diameter?
  • beachbum  

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  @Kwagga Think I just saw the same video. I mean how many Yap dome home videos could there be, right? Here is the one I found. Youtube Video
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  Can you tell me what foaming agent can be used in Australia thanks
  • longgrazz  

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  @Zander earth choice dishwashing liquid is great. The earth choice laundry detergent however is a disaster. Failcrete all round. Another good one available in Longreach is “Trucking Blue. Not only makes fine aircrete but the car sparkles. Might be harder to get out your way. Transporting cattle and mining gear on the highways, unsealed roads and dust paddocks of Outback Oz the only sign of life the a million insects dead on the windscreen, you need a heavy duty cleaner to spruce up. Cheers