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Instruction The frames of the film merge for us into continuous movement due to ...
Aerated concrete is an artificial stone that has recently been used in the construction world. It has high thermal conductivity and strength, is light and easy to install, has found its application in the construction of partition walls and wall blocks. Due to the exact parameters of aerated concrete floors, an even and smooth coating is provided, which does not require subsequent finishing. Aerated concrete walls are prefabricated prefabricated slabs. The great demand for such products has arisen due to their environmentally friendly components that do not affect human health.
Where are they used?
Aerated concrete slabs are used in the installation of ceilings between floors of buildings, and also serve to build walls. Aerated concrete structures are used in the construction of houses, the height of which does not exceed three floors. For floors, aerated concrete blocks are used with technical characteristics suitable for the weight of the vaults.
Advantages
- Aerated concrete blocks do not have dimensional errors. Thanks to this, the surface is smooth, which significantly reduces the cost of finishing buildings. But there is one condition - the walls must also be without reliefs, cracks and potholes. To get rid of defects, putty and grinding are used.
- Mounting an aerated concrete slab, you do not have to spend a lot of time, make great efforts.
- The advantages of this material include the lightness of the blocks, which during operation do not exert a load on the load-bearing walls of buildings.
- When installing aerated concrete elements, a small amount of auxiliary equipment is used.
- When using aerated concrete in the construction of houses with a small number of floors, the following characteristics of the material are taken into account: strength, fire resistance, sound insulation, thermal insulation and moisture resistance. The material is odorless, with environmentally friendly components.
- The advantage when working with aerated concrete floors is their convenience when installing balcony bases.
disadvantages
Main types
Foam concrete building blocks are autoclaved and non-autoclaved. The second type is the best in terms of price and quality characteristics. Using autoclave plates, you need to be prepared that after installation, during operation, they "age". In the production of autoclaved slabs of cellular aerated concrete, lime is used, due to which the materials harden as a result of pressure and temperature. In the preparation, cement is used as a binder, as a result, the hardening of the particles occurs naturally.
Floor slabs for aerated concrete are of the following types:
- monolithic;
- aerated concrete;
- wooden beams;
- reinforced concrete slabs;
- metal beams.
When using aerated concrete slabs, a reinforced annular belt is required. The overlap of reinforced or aerated concrete is a monolithic structure consisting of grooves into which slabs are inserted. When working with aerated concrete slabs, they are laid on a reinforcing layer. At the same time, the reinforcing structure is treated with anti-corrosion coatings..
The sizes of the plates are different, but the main condition is that they should protrude 20 cm beyond the span. Prefabricated ones are also used, which are manufactured in factories; they are more economical than monolithic ones. Aerated concrete structures differ in light weight, which cannot be said about reinforced concrete ones.
Monolithic ceilings with a thickness of about 3 centimeters include a reinforcing mesh filled with concrete. Such designs of aerated concrete houses have a different shape, which is not similar to slab ones. Single floors endure a large load, which is a plus, the disadvantages include their high cost and labor intensity.
There are also prefabricated monolithic structures, which include prefabricated aerated concrete floors, the top of which is reinforced.
Installed a couple of centimeters below the floors to avoid pressure and cracking. Aerated concrete floor slabs can act as door and window lintels. With a wall thickness of more than 5 cm, prefabricated jumpers are used, the length of which should be 1 centimeter more than the opening.
Houses have been known on the market for quite a long time from lightweight concrete: aerated concrete and foam concrete.
If you have firmly decided to build from gas blocks - just build, good construction for you. But if you are in doubt - evaluate our offer.
Reasons for the objectivity of doubts about the house of aerated concrete:
- high foundation requirements, the need to study soils (geology and geodesy);
- cracks in the walls as a result any mistakes (it's better to say this: any mistakes eventually lead to cracks in the walls) - a sharp decrease in security and the inability to sell a cracked house - a mistake to build a house from aerated concrete without a professional technical supervision by the customer(that is, it is paid by the Customer and he submits to the Customer!);
- low fire safety of a house made of aerated concrete - after exposure to even a small fire, aerated concrete collapses already at 600 degrees and the walls must be dismantled.
- in reality, a turnkey aerated concrete house is being built at least 1.5 years from the beginning of construction;
- high interior decorating costs- plastering and puttying of walls;
- be sure to buy high-quality aerated concrete with high geometry ( see below a video from Germany about how hard and hard the quality of gas blocks is achieved);
- obligatory fulfillment of all requirements of aerated concrete manufacturers(requirements are listed at the bottom of this page) - for this, control by the Technical Supervision on the part of the Customer is needed;
- strict requirements for delivery and warehousing blocks, the need to use trucks with air suspension (didn't you know?), the need for lifting equipment to work on the construction site;
- high heating costs houses made of aerated concrete in the absence of main gas ( at the bottom of the page is the video "How they build in Finland", pay attention to the last phrases in the video - in recent years in Finland they have not built houses using any stone (heavy) technologies. At the same time, Finland has the most stringent requirements for heat engineering and the closest climatic conditions to Russia).
The importance of choosing the right aerated concrete in a short video from the German plant Yutong:
What to do if:
- there is no time to build an individual house for a long time, or there is no way to control the construction yourself or through independent technical supervision;
- the budget for the right aerated concrete house is too large;
- there is no main gas for heating, or they ask for an indecent amount for gas - it is expensive to heat houses made of aerated concrete with electricity;
- there is no way to drive to the construction site on heavy equipment;
- soils are water-saturated or have a weak bearing capacity;
- the construction area has seismic activity.
- Construction fully finished house on a reinforced concrete slab Full construction for 3-4 months.
- The difference in cost with a house made of aerated concrete (if it is built according to the norms) with an area of 180-200 m2 - SAVE more than one million rubles.
- Our modern, capital and solid the house can be heated with electricity at no great cost.
- We make a smart ventilation system and a smart home control system.
- Author's design project of the facade. And we can make it come true.
- Maybe basement and basement construction.
In addition to the price, a significant advantage of stone panel houses is their complete aadaptation to cold climate conditions and lack of main gas for heating .
It will be much easier to warm up a house made of stone Neo LSU panels with electricity than a house made of aerated concrete due to the high thermal inertia of the aerated concrete box. Tested by experience.
In the photo, our houses made of Neo LSU stone panels.
Let's get back to aerated concrete. Why do we need technical supervision when building a house from aerated concrete? The reason is the strict observance of the mandatory requirements for the construction of houses from aerated concrete (for example, the company Ytong).
MANDATORY requirements for transportation, unloading and storage of aerated concrete:
- transportation of blocks only on vehicles with air suspension (dramatically reduces the traffic fight);
- hauling each row during transportation with a transport screed (to prevent shedding of the edges of the blocks);
- proper unloading using S-shaped hangers or traverses (other unloading is prohibited to avoid scrap blocks when the pallet is displaced when it is lifted);
- storage of aerated concrete blocks only on a prepared flat area (since it does not work for a break and breaks);
Compliance with the requirements for transportation, unloading and warehousing allows you to claim compensation for excess production and transport damage in pallets from the manufacturer's plant (if the failure of aerated concrete blocks as a result of delivery was more than 5%).
MANDATORY requirements for the production of construction and installation works:
- bearing wall thickness not less than 250 mm for two floors and 375 mm for three floors;
- the thickness of the interior partition is at least 150 mm (to comply with sound insulation standards);
- construction only on specialized adhesives(the use of masonry mortar is unacceptable due to a sharp decrease in the heat engineering of the wall and due to a decrease in the mechanical properties of the wall by 4-7 times);
- applying glue not only to horizontal seams, but also to vertical ones (this requirement is absent in Europe, but in Russia this makes it possible to reduce the airflow of aerated concrete walls, since the accuracy of cutting blocks of 1-2 mm does not completely eliminate the appearance of through cracks); Use only winter adhesives in winter, and only summer adhesives in summer;
- obligatory creation of a closed reinforced concrete belt after each floor for tying all the walls into a single construct;
- obligatory reinforcement of walls under all window openings;
- mandatory use of concrete lintels (not a metal corner) over any openings in the walls;
- observance of the maximum permitted speed construction and curing of concrete to curing ( the correct term for the construction of the box is at least 5 months);
- the use of only permitted types of foundations that completely exclude movement and settlement (recommendation of the factory: do not plaster the facade for at least 1 year to assess the formation of cracks on the walls);
- lining the house with bricks only through the ventilated air gap 50 mm;
- do not use when insulating the facade of a house with extruded polystyrene foam due to its low vapor permeability;
- proper drying at home inside for finishing (manufacturer's recommendation 6-9 months), since the block has a moisture content of 30% and it must first decrease (wet aerated concrete has a low bearing capacity and must be loaded carefully), then the humidity must even out over the entire mass of the block (otherwise there will be shrinkage cracks) and then you need to bring the humidity to 16% and only then start finishing (otherwise cracking of the decorative finish is possible);
- selection of facade finishes according to the coefficient of vapor permeability: not less than 0.24 for aerated concrete density of 400 kg/m3 and 0.21 for density of 500 kg/m3.
Fulfillment of all these requirements for the production of construction and installation works allows you to build a gas-block house that will not be subject to cracking.
Mandatory requirements lead to an objective situation:
- you will move into a house made of aerated concrete no earlier than in 1.5 - 2.0 years;
- need independent and paid by the Customer Technical supervision or daily control at the construction site;
- in order for a house made of aerated concrete blocks to be warm, it is necessary to fulfill the requirements for the thickness of aerated concrete walls, exclude vertical and horizontal gaps between the blocks, exclude cracking of the blocks themselves, and make the correct facade finish. Against the backdrop of tightening requirements for heat engineering in Russia (according to the order of the Ministry of Construction in 2018, the norms were increased by 20%, the next increase by 40% in 2023, and by 50% in 2028. At the same time, even the requirements for heat engineering in 2017 (before the tightening of standards ) required a thickness of aerated concrete walls of 400 mm for the Moscow region. What will happen by 2028? The thickness of the aerated concrete wall will have to become a meter thick. It is because of this that Finland stopped building houses using any heavy technology - see the video at the end of the page.
- As a result, the right aerated concrete house in the end always turns out to be expensive. It simply cannot be cheap based on the results of fulfilling all the norms.
Video about houses in Finland. Pay attention to the words at the end that in Finland, in recent years, heavy houses have not been built.
Worthy and beneficial.
More than 570 built objects in Russia
All products made of cellular concrete must be manufactured according to the same technology and in the same type of interchangeable forms, using a cutting system, in which the aerated concrete mass of raw concrete with a volume of 5-15 m3 is cut into products of the required dimensions.
The following products are made from autoclaved aerated concrete:
Small wall blocks;
- non-reinforced large wall blocks;
- reinforced large wall blocks;
- wall panels are integrally molded;
- composite wall panels;
- bulk blocks;
- partition boards;
- interfloor floor slabs;
- coating slabs;
- heat-insulating plates;
- jumpers;
- acoustic plates;
- decorative plates.
2.1. small wall blocks
Non-reinforced small blocks of aerated concrete are manufactured and accepted in accordance with GOST 31360. They have compressive strength classes not lower than B1.5 and density grades not higher than D700.
Blocks are made I and II categories.
Dimensional deviation
BlocksIcategories:
Length±3mm;
- in width ±2 mm;
- in height ±1 mm.
BlocksIIcategories:
Length ±4 mm;
- width ± 3 mm;
- in height ±4 mm.
The laying of walls from small blocks is carried out on mortars or on glue. External load-bearing, self-supporting and curtain walls, as well as internal load-bearing walls and partitions can be made from aerated concrete blocks.
For normal operating conditions, the blocks must have a frost resistance of at least F 25, for wet conditions - not lower F 35. In the regions of the Far North with design temperatures below -40 ° C, frost resistance marks should not be lower, respectively F 35 and F 50.
2.2 Large wall blocks
Non-reinforced (according to GOST 31360) include products with maximum dimensions up to 1500 mm long, up to 1000 mm wide, up to 600 mm thick. They are designed for direct mounting of large-block and large-panel buildings or for pre-assembly in panels.
Large blocks are used for the construction of external and internal walls of all types: hinged, self-supporting and load-bearing. Blocks of external walls are recommended to be finished with a surface layer at the factory and delivered to the construction site in finished form.
The frost resistance mark should be at least under normal operating conditions F 25, in wet - F F 35 and F 50.
Blocks I and II category, the same dimensional deviations are allowed as for small blocks.
2.3 Reinforced large blocks and wall panels
Reinforced large blocks and wall panels are manufactured in accordance with GOST 11118.
A large reinforced block is an element with an area of less than 1.8 m 2, reinforced with structural and working reinforcement, designed to withstand technological, transport, installation and operational loads. The wall panel can be integral and composite.
One-piece exterior wall panel is a prefabricated product with an area of at least 1.8 m 2 .
A composite wall panel is a panel assembled from original elements (including large blocks on glue, mortar, by welding steel embedded products or using ties.
The original element is a reinforced large block, combined into a mounting panel.
Composite panels are more preferable, since only they allow the use of cutting technology, are more crack-resistant, require less reinforcement consumption, use molds and an autoclave better.
To increase crack resistance, prestressed reinforcement can be provided, as well as strands used for pre-assembly and installation.
The density grade of the used aerated concrete ranges from D400 to D800, the compressive strength class is from B1.5 to B7.5.
Panels can be hinged, self-supporting and bearing. For external longitudinal walls, hinged wall panels should be taken, allowing the use of the lightest and most efficient aerated concrete of the D400 grade. Single cut exterior walls are delivered fully finished with fitted joinery and glazing. The outer section should provide an expressive architectural appearance of the facade and its durability.
The frost resistance mark must be at least for normal operating conditions F 25, in wet - F 35. For the conditions of the Far North, respectively F 35 and F 50.
Installation of panels can be carried out on mortar, adhesives (mastics) and dry with the help of elastic gaskets. As mounting devices, self-gripping traverses should be provided. Composite panels are lifted by tie rods, which can be removed after installation. It is recommended to make the joining edges of the panels flat, without ridges and grooves. Blowing and wetting are prevented by sealing with mortar, poroisol and elastic mastics. Anchor connections between panels and adjacent structures should be made without molded embedded parts, and the workability of cellular concrete should be used.
Channels and grooves for hidden wiring and utilities are recommended to be factory-made with electrified cutters and drills. The calculation of wall panels for strength and deformation should be carried out in accordance with STO 501-52-01-2007.
Transportation of panels should be carried out by panel carriers in a state fixed from dynamic influences with the help of elastic gaskets. The use of mounting "from wheels" is recommended. During transportation and storage, the panels must be protected from moisture and mechanical damage. Other technical requirements are set out in STO 501-52-01-2007.
2.4 Volume blocks
Volumetric blocks (block rooms) made of aerated concrete are a new progressive type of construction. They are assembled on glue and strands from separate flat elements obtained by cutting technology. The blocks are made in the size of a room and look like a box closed on all sides. They can be suspended (hung on the frame) and bearing. In the first case, the thickness of the inner walls must be at least 8 cm. For load-bearing blocks, the thickness of the inner walls is assumed to be at least 10 cm and the compressive strength class is at least B3.5.
The same minimum thickness and class must be the floor elements in both options. The size of the air gap in the walls and ceilings should be at least 5 cm. It is recommended to make the outer walls of a hinged structure, they transfer their weight to the ceilings and transverse load-bearing walls.
Installation of blocks is provided dry in order to ensure the possibility of winter construction at any temperature. Volumetric blocks are supplied for installation fully finished. Finishing is carried out either at the cellular concrete plant, if it is connected to the construction site by a good road, or at the on-site closed landfill, where the pre-assembly of blocks is carried out.
Loading of volumetric blocks is carried out with the help of a balancing traverse, which ensures the absence of skews. The blocks are transported by trailers with soft platform suspension.
During installation, the blocks are protected from moisture.
2.5 Panels for partition walls
Aerated concrete partition panels are manufactured in accordance with GOST 19750.
Partition panels (non-bearing) made of aerated concrete can be multi-row cut and single-row cut.
Reinforced slabs (panels) of partitions are made one floor high, with a thickness of 8 to 30 cm, a width of 60 cm from aerated concrete grades D400-D800, classes B1.5-B7.5. Reinforced with a central cold-drawn wire mesh for thicknesses from 80 mm to 120 mm or two meshes for thicknesses from 160 to 300 mm. Frost resistance - not less than F 15. In wet rooms, the boards are protected by a paint-resistant hydrophobic vapor barrier.
The panels are joined with adhesives and mastics. Attached to adjacent cellular concrete structures with nails. Driving pins, dowels, staples and screws. Should be lifted with pincer grips (without embedded loops).
Delivery and storage are carried out on pallets in packages protected from moisture.
Technical requirements are set out in GOST 19570 and STO 501-52-01-2007.
2.6 Floor panels
Floor panels are made in accordance with GOST 19570 from aerated concrete of classes from B2 to B10 and density grades from D500 to D1200. THEIR width can be from 600 to 1800 mm. Length 2400-6000 mm, thickness 140-250 mm. With a thickness of 220 mm, they become interchangeable with heavy-weight concrete hollow core panels and can be used in typical brick houses, as well as in their reconstruction. Frost resistance - not less than F 25.
Reinforcement can be carried out with prestressed reinforcement (wire or rod), strained on cellular concrete or reinforced concrete bars (bar reinforcement).
Embedded mounting loops can be provided if tongs and traverses are not used.
When calibrated, the panels can be used for "dry" mounting, i.e. without the device of supporting mortar beds (if the support also occurs on calibrated surfaces). The longitudinal and transverse seams between the panels are reinforced and filled with cement mortar, and reinforcing cages are laid above the supports in the longitudinal seam.
Grooves, channels and openings for electrical wiring and utilities can be cut on the construction site using electric cutters, drills, circular or chain saws, and hand plows. Hammering concrete with an impact tool is prohibited. Grooves and other weakenings should not reduce the bearing capacity and rigidity of products below the required values.
Calculation of floor decking is carried out for strength, stiffness and crack opening in accordance with the standards for designing structures made of cellular concrete and STO 501-52-01-2007. The maximum design load with a length of 6 m should not exceed 600 kg / m 2 (6 kPa) (in excess of its own weight).
Storage and transportation are carried out in the working position (flat) on gaskets, protected from moisture.
Technical requirements are set out in GOST 19570 and STO 501-52-01-2007.
2.7 Cover panels
Aerated concrete coating panels are made of concrete classes from B2 to B3.5, grades D400-D600. Their length is from 2.4 to 6 m, width - from 0.6 to 1.8 m, thickness - from 250 to 400 mm.
To increase the thermal insulation ability of coatings, it is recommended to make them ventilated. Ventilation becomes necessary in panels laid over wet rooms, even if there is a bottom vapor barrier.
Frost resistance of the material of ventilated panels should be at least F25, non-ventilated - at least F35, respectively, for the conditions of the Far North - F35 and F50.
The load-bearing panels of the coatings are reinforced based on operational loads (possibly with prestressed reinforcement).
Non-bearing panels (laid on a reinforced concrete base) are reinforced from the conditions of perception of stripping and transport loads. The upper plane of the panels (including above the channels that do not come to the surface) is reinforced with an anti-shrink mesh made of cold-drawn wire with a diameter of 3-4 mm with a cell side of 10-15 cm. should come to the surface and be arranged by milling.
The minimum cross-sectional area of the channel is 15 cm2, while the maximum step is 20 cm and increases in proportion to the cross-sectional area of the channels. Mounting loops are not provided in the case of using tongs and traverses.
Covering panels with a smooth upper plane are recommended to be covered with a layer of bitumen at the factory or glued with roofing material in order to simplify roofing work and reduce moisture during transportation, storage and installation.
In the case of calibrated load-bearing panels and support surfaces, dry mounting is allowed. Anchoring is carried out using strip anchors connected to the supporting structures, nailed to the covering panels. During the installation of the roof panels, the longitudinal and transverse seams that serve to pass the channels are monolithic only to the level of the bottom of the channels. Reinforcing cages are inserted into the solution of longitudinal seams above the supports.
Coating slabs are calculated for strength, stiffness and crack opening according to STO 501-52-01-2007.
Transportation and storage are carried out in the working position, on gaskets, with the adoption of measures to prevent moisture. At the same time, the natural drying of the panels before installation should not be impaired.
2.8 Thermal insulation boards
Heat-insulating slabs are manufactured in accordance with GOST 5742, with dimensions of 100 * 50 * 8-24 cm (graded every 2 cm) from cellular concrete of D350 and D400 density grades and compressive strength classes B0.5 and B0.75, respectively.
For civil engineering, taking into account the unification, the introduction of cutting technology and the achieved quality of cellular concrete, the recommended dimensions are 600 and 1200 mm in length, 200 and 300 mm in height and 50, 80, 100 and 160 mm in thickness. The compressive strength class for bulk grades D350 and D400 must be at least B1 and B1.5, respectively.
Release humidity of thermal insulation boards that can dry out during operation (attic floor, ventilated roofs, external wall cladding, as well as basement ceilings) should be no more than 25% (by weight). Release humidity of the sealed thermal insulation should not exceed 12%.
Frost resistance should not be lower than 15 (for the Far North - F 25).
Heat-insulating boards must be made using cutting technology with subsequent calibration and mounted on glue.
Thermal insulation slabs can serve as a formwork shield (fixed formwork) when concreting monolithic walls, subsequently performing decorative and insulating functions.
Additional insulation slabs are sawn off from the main slabs with a hacksaw, circular or chain saw.
Thermal insulation boards are supplied on pallets in packages protected from moisture, but with the possibility of natural drying.
2.9 Jumpers
Aerated concrete lintels are used to block window and door openings in external and internal walls made of cellular concrete. In external walls, lintels are used only in the case of block masonry.
Lintels are made of aerated concrete of density grades from D500 to D700, compressive strength classes B2-B5. The thickness of the jumpers is 200-250 mm. The length can vary from 1200 to 3600 (with a gradation of 0.3), height - from 200 to 400 mm.
The lintels can be non-bearing, in which case they are structurally reinforced, and load-bearing with design working reinforcement in the tension zone. Lintels must have a release moisture and frost resistance corresponding to adjacent wall elements.
Jumpers must be mounted with tongs (without mounting loops) or manually (for jumpers weighing up to 60 kg).
Leaning occurs on mortar or adhesive (for calibrated products) beds or reinforced concrete belts. The support depth of the jumpers must be at least 150 mm.
Lintels are calculated for strength in vertical and inclined sections in accordance with the design standards for structures made of cellular concrete or STO 501-52-01-2007.
Their transportation and storage are carried out in the working position in packages protected from getting wet.
2.10 Acoustic plates
Autoclaved aerated concrete has a good sound-absorbing ability and can be used as an acoustic cladding for the halls of public buildings, restaurants, shops, and playrooms.
Acoustic slab density grade D400, strength class not less than B1.5, dimensions 400x400, 450x450, 450x600 mm, with a thickness of 50 mm. Tolerance in length, height and thickness up to 2 mm. Humidity and frost resistance are not standardized. The average sound absorption coefficient in the range often 100-3200 Hz should be at least 0.5. To increase the acoustic properties in slabs with a thickness of 50 mm, grooves with a section of 20x20 mm (with a step in the axes of 40 mm) can be cut, filled with mipore (foam rubber).
The plates are fixed to the ceiling with brackets or screws, to the walls - with glue or mastic. Delivery is made in packages in cardboard containers of 1-1.5 m 3 in one package.
Due to the workability, durability and cost-effectiveness of aerated concrete, decorative slabs with relief and pigment applied to them for interior decoration of public buildings can be made from it.
Grade according to the density of decorative plates D500-D700, strength class B1.5-B2.5, length 600 mm, height 200 mm, thickness 50-80 mm. Tolerance in length and height up to 2 mm, in thickness up to 1 mm. Release humidity and frost resistance are not standardized.
Fastening to the walls is carried out on adhesives and mastics. Delivery is carried out in packages on pallets.
Aerated concrete is a stumbling block for a considerable number of near-construction disputes. Despite the battles, many professional builders believe that it is a good, if not ideal, building material. As, however, and all the rest. To decide to build a house from aerated concrete blocks, we must remember that the material has many useful qualities, has already become quite widespread.
The choice of wall aerated concrete (gas silicate) blocks Source stroyres.net
A bit of history
For centuries, people have used natural building stone - tuff - to build houses. It was valued for its lightness, ease of processing and the ability to retain heat well. Since the 19th century, scientists have tried to reproduce these qualities by experimenting with concrete mixtures. Important milestones on the way to the creation of modern aerated concrete are considered to be the consistent work of several researchers:
Hoffmann engineer(Czech Republic). In 1889, he conducted a series of experiments with cement mortar, adding acids and salts to it. During solidification, the released gases formed a characteristic porous structure.
American Owlsworth and Dyer. In 1914 they were the first to use aluminum and zinc salts. The reaction proceeded with the release of hydrogen, which formed a homogeneous porous structure. The method laid the foundation for future technology.
Architect Erickson. In 1922, the Swede patented a method for the production of cellular concrete using aluminum powder, becoming the godfather of modern autoclaved aerated concrete. The first aerated concrete for the construction of industrial and residential buildings began to be produced in 1929.
Modern project of a house made of gas silicate blocks Source buildhouse.info
In the USSR, the industrial production of cellular concrete was also established in the 30s. The first autoclaved block aerated concrete was produced in Riga in 1937; buildings built from these blocks still stand in the city. In the post-war 50s, aerated concrete helped to restore the destroyed infrastructure, both in the USSR and in Europe. In modern Russia, more than 80 modern manufacturing plants satisfy the needs for material.
Composition and technology
Aerated concrete is a representative of the category of cellular concrete, building materials, different in properties and features of operation. The unifying characteristic is the porous structure, low weight and low density. In the production of aerated concrete, the following components are used:
astringent. Portland cement.
Filler. Quartz sand.
Gasifier. Aluminum powder or paste.
Industrial purification water.
Enhancers. Lime, gypsum, industrial waste (slag, ash).
Autoclave blocks Source ar.decorexpro.com
The production of aerated concrete begins with mixing the ingredients and pouring the mixture into molds. The chemical reaction results in the formation of hydrogen. The gas increases the volume of the mixture (swells it) and forms pores. After the reaction is completed, the mixture sets, it is removed from the molds and cut according to the standard. Further processing goes in two ways. Depending on which drying method is used, one of two types of aerated concrete is obtained:
autoclaved(synthesis) hardening. Blocks gain hardness (steam) in autoclaves (devices that create high pressure in an environment saturated with water vapor).
non-autoclaved(hydration, air) hardening. Blocks harden at atmospheric pressure in drying chambers.
Classification
According to the standard, cellular concretes (including aerated concrete) are divided into three types according to their functional purpose:
Structural. Density ranges from 1000–1200 kg/m³.
Structural and heat-insulating. From 500 to 900 kg/m³. The D500 brand says that in 1 m³ part of the volume is filled with 500 kg of solid material, the remaining volume is air filling the voids (cells).
Thermal insulation. From 200 to 500 kg/m³.
Using blocks increases the speed of construction Source geo-comfort.ru
Specifications
Aerated concrete is an example of the optimal ratio between the main performance characteristics:
strength. Despite the low density (specific gravity), the strength is sufficient for the use of aerated concrete in the construction of load-bearing walls.
Ease. The lightness of aerated concrete is due to porosity, which can reach 85-90% of the volume of the material.
Low thermal conductivity. Good thermal efficiency is also a result of the porosity of the material. Aerated concrete boasts the lowest thermal conductivity, 0.12 W / m ° C (dry).
Crafting mistakes
Having found on the Internet a lot of tips for the production of aerated concrete with their own hands, and making sure that they are quite feasible, many decide to start their own production. At the same time, home craftsmen do not consider it necessary to strictly comply with technological standards, but they always find those who want to purchase a product at dumping prices.
Small production - no warranty Source beton-house.com
On our website you can get acquainted with the most popular projects of houses from aerated concrete blocks from construction companies presented at the exhibition of houses "Low-Rise Country".
The use of high-quality raw materials and technological equipment in factory production makes it possible to obtain aerated concrete products with stable physical and chemical characteristics:
exact dimensions and correct, with minimal marriage, form.
Given physical and mechanical parameters.
Uniform material density, which is confirmed visually (uniform distribution of air cavities).
Chemical inertness of the material, which is confirmed by laboratory control throughout the production cycle.
The conditions of handicraft production cannot provide manufacturability and control at the level of a modern workshop. Hand-made aerated concrete blocks are distinguishable to the naked eye: the cells (cavities) are unevenly distributed, and the geometry leaves much to be desired. Sometimes such products smell noticeably of chemistry (often lime). The use of blocks made in artisanal conditions is likely to reduce the cost of construction, but is guaranteed to become a source of serious problems:
Blocks with arbitrary density and composition have increased fragility and with a high degree of probability will begin to crack in the first year of operation of the house.
Rough seams will cause heat loss Source bg.decorexpro.com
Blocks with non-ideal geometry it will not be possible to put on a special glue; mortar must be used. Seams with a thickness of 1 to 2 cm will become cold bridges, reducing the thermal efficiency of housing and contributing to the freezing of walls.
Blocks with residual undecomposed lime will have a persistent chemical smell (and affect the health of the people living in the house). Excess lime can start the process of corrosion of the metal in the wall.
Advantages and disadvantages of the material
A country gas silicate house has the same strengths and weaknesses as the original material. Based on the structure of aerated concrete, many advantages can be distinguished:
Cheapness. Due to the low consumption of cement in the manufacture of products.
Construction speed. The blocks have a significant size, and weigh 3-5 times less than a brick of the same volume. This allows you to build 1 m² of wall in 20-25 minutes, which is unattainable in the case of brickwork.
Construction costs. Savings are obtained through the rational use of working time and building materials.
Aerated concrete can be processed manually Source kamtehnopark.ru
service of construction of houses from aerated concrete blocks
Low thermal conductivity. According to this indicator, aerated concrete is 2-3 times better than brick. A 37.5 cm thick block wall retains heat as well as 60 cm thick brickwork.
Ease of processing. Blocks are easily cut with any hand tool, sawn, milled and chipped. This flexibility allows complex architectural designs to be created.
fire resistance. Aerated concrete is characterized by a high degree of fire resistance and belongs to the combustibility group NG (not combustible). When exposed to a flame with a temperature above 100 ° C for two hours, the aerated concrete wall begins to lose strength and crack to a depth of 3-4 cm (enough time to leave the house and call the fire brigade). The wooden house will burn to the ground during this time.
Vapor permeability. High. Due to the presence of interconnected voids, the material successfully regulates the humidity in the room (breathes).
Environmental friendliness. The lime and aluminum powder used in the production are converted into inert solids after a gassing reaction. Therefore, the material made according to all the requirements of the technology does not emit any volatile substances into the air.
It is interesting! At various construction forums, one can often find references to a certain table of coefficients for the environmental friendliness of materials. Even some figures are given - for example, for expanded clay, this coefficient is 20, for brick - 10, aerated concrete - 2, and the leader and standard is wood - it has this value equal to 1. In practice, the existence of such a table is not confirmed in any official document , although if we consider the materials precisely in terms of the release of any substances into the air, then there is some truth in such a division.
Durability. In the Scandinavian countries, Germany and France, there are many aerated concrete houses built 40-50 years ago and still showing no signs of destruction. Such resistance is due to the quality of the prefabricated material and installation carried out in compliance with the technology.
Post-war aerated concrete house Source bwncy.com
Frost resistance. Aerated concrete resists cyclic freezing well.
Features of aerated concrete blocks determine the weaknesses of the structure:
Bending strength. Aerated concrete is characterized by a relatively low coefficient of ultimate deformation (0.5–2 mm/m). The deformation of the foundation, which goes beyond these limits, leads to the appearance of cracks in the wall of the house. The means of struggle will be the construction of a solid foundation with a monolithic strapping or mesh reinforcement, strapping of floors and reinforcement of masonry. It is also not recommended to build private houses above 3 floors.
fasteners. Nails, anchors and self-tapping screws fit perfectly into the aerated concrete wall, but they stay disgusting there. A characteristic drawback of all cellular concretes is corrected by using special fasteners for porous surfaces (steel, nylon, frame). You should also pay attention to the installation of windows and doors (if installed incorrectly, they can loosen over time).
Adhesion(adhesion to finishing materials). It is low, therefore, before plastering, the wall must be prepared (make reinforcement or put a primer layer).
Exterior finish of the facade with plaster Source hug-fu.com
On our site you can find contacts of construction companies that offer house design services. You can directly communicate with representatives by visiting the exhibition of houses "Low-Rise Country".
Shrinkage. Shrinkage of non-autoclaved aerated concrete reaches 2 mm / m, autoclaved - up to 1 mm / m.
In order for the erected house to serve for a long time and without problems, it is necessary to take into account the features of the material:
Hygroscopicity. A porous wall is able to absorb and release moisture (as, for example, a wooden one). To protect the facade from excessive moisture, the walls are lined, best of all - with ventilation.
Heating. A house made of aerated concrete can significantly reduce heating costs, but it must be borne in mind that the higher the grade of aerated concrete, the worse its thermal insulation properties. Energy efficiency can be improved by simple plastering.
Purge. Since aerated concrete is a fairly large building blocks, the likelihood of poor-quality installation increases, even taking into account the excellent geometry of the products. For example, if the glue is too thick, then it does not completely fill the space between the blocks and through cracks form. If there is such an opportunity, then after construction it is recommended to conduct a thermal imaging survey of the house in order to know if there are joints and seams that need to be repaired.
Aerated concrete cottage with natural stone cladding Source pinterest.ch
Myths about technology
Many have met not the most flattering reviews about aerated concrete and the performance of houses that had the misfortune of being built from it. Such judgments and conclusions often have little in common with reality and are caused by a misunderstanding of the characteristics of the material and technology. Most often you can hear such "expert" opinions:
Aerated concrete walls are prone to cracking. Cracks can appear not only in aerated concrete walls, but also, for example, in brickwork. After the examination, we have to admit that in most cases the cause of the defect is not at all the quality of aerated concrete. Most often, the culprit is a poor-quality foundation, the design of which did not take into account the characteristics of the soil and the location of groundwater. Another reason may be reinforcement errors (both walls and foundation). The quality of aerated concrete will play an unfortunate role only if garage-made material was used.
Buildings made of aerated concrete need indispensable insulation. If, when developing a house project, the thickness of wall structures was laid taking into account the norms of SNiP 23-02-2003 (on the thermal protection of buildings), additional insulation is not required. But since aerated concrete houses definitely need facade decoration, insulation is often “at the same time” mounted.
Finishing requires the arrangement of a ventilated facade Source bankfs.ru
Gas blocks for the home - a very fragile material, which breaks from a hammer blow. The same brick can also be split by applying a certain force. According to SNiP, for low-rise construction (up to three floors), aerated concrete blocks of the D500 brand are recommended, which are strong enough and at the same time light and warm. D400 brand material is more fragile and warm, D600 brand material, on the contrary, is stronger and colder. Houses built taking into account technological features perfectly cope with the emerging loads, even in seismically active areas.
Aerated concrete absorbs moisture like a sponge, therefore, a freshly built facade requires prompt waterproofing. One of the main features of the material is its gas and vapor permeability, which, however, does not differ much from the characteristics of wood in terms of performance. Like wood, aerated concrete is able to absorb moisture and then return it, regulating the microclimate in the rooms. Both materials have a humidity corresponding to the humidity of the surrounding air, and since concrete does not dissolve in water, nothing threatens gas blocks. Exterior walls will not get excessively wet in cottages with year-round use and properly equipped cladding (not preventing moisture circulation).
Video description
About the construction of gas silicate blocks in the following video:
Aerated concrete block gets wet and immersed in water, therefore not suitable for the construction of suburban housing. Strange logic, if you remember that the foam remains on the surface of the water, and the brick instantly goes to the bottom. The degree of water absorption of an aerated concrete wall during operation is in no way related to buoyancy, these are two different signs.
Living in a house with aerated concrete walls is dangerous, since the composition of the material includes lime and aluminum, and the rooms sometimes smell of lime. These elements are part of the original mixture; then they enter into a chemical reaction (reaction of transformation, transformation) with other components. The output is an artificial stone, aerated concrete, in which there are no original elements. Industrial production is characterized by an accurate dosage of the starting materials and high-quality drying, as a result of which only safe silicates remain in the material. The smell of lime appears in garage aerated concrete, when the components are measured "by eye" and more lime is added than necessary.
Design features of a typical aerated concrete project Source stroyres.net
When developing a project for a country house made of aerated concrete parts, they rely on the characteristics of the material. In order for housing to come out comfortable and durable, the following points are taken into account:
Wall thickness. Set by constructive necessity. The optimal thickness of load-bearing walls in the climatic conditions of central Russia ranges from 300-400 mm, interior partitions - 100-150 mm.
Suitable Foundation. For walls made of aerated concrete, a reliable and stable foundation is important. A monolithic slab base is usually recommended; it is beneficial to use on various soils.
Video description
About a typical gas-block house in the following video:
Roof. Pitched or flat, the roof needs to be properly installed on aerated concrete walls. Lightweight construction with metal, corrugated sheet or bituminous tiles as a roof is preferred.
The need for conservation. Autoclaved aerated concrete masonry is not carried out at temperatures below -5°C. If cold weather sets in, the house is conserved; it is desirable that by this moment he already had ceilings above the first floor. The walls are covered with a waterproofing film, in the same way as pallets with blocks (it is better if they are packed in factory shrink tape).
Arrangement of the roof of an aerated concrete house Source bankfs.ru
Design subtleties
Aerated concrete is a material that offers the widest possibilities for architectural solutions, one has only to remember the famous Dancing House in Prague. The following requirements are imposed on the design of a country cottage made of aerated concrete:
Originality. Details of the architectural style are able to convey the taste of the owners and emphasize their individuality. An exclusive look is often achieved by combining modern and traditional styles.
Practicality(functionality). Currently, aerated concrete houses are being designed with a well-thought-out layout and with any additions - a garage, a terrace (including on the top floor), an attic, a glazed bay window or a balcony.
Comfort. The concept of comfort can be different, and the interior of a house made of aerated concrete blocks can be decorated in any style, from traditional classic to ascetic-minimalistic. Often the choice of the customer is a cozy country style, picturesque Provence or an energetic loft.
Modern design with oriental touches Source pinterest.com
Projects and prices of turnkey aerated concrete houses
If you decide to build a house from aerated concrete, its price will in any case be more budgetary than a similar brick cottage. Many variables will affect the cost:
Project type. You can buy a popular standard project (with ready-made documentation) or order an individual development that takes into account personal preferences.
Brands of building materials. The price depends on the manufacturer (domestic or foreign) and the volume of purchases.
The complexity of the architectural solution. It is determined by the area and number of floors of the project, as well as the type of foundation and roof.
Site relief. If there is a slope on the site, the project will have to be finalized.
Video description
About the thermal imaging inspection of a gas-block house in the following video:
By choosing the construction of a turnkey house from aerated concrete blocks, you will be able to appreciate all the advantages of this service, because from the moment the contract is signed, all current issues related to the construction of the house become the concern of the contractor:
Inevitable improvements and changes to the project.
Geological and geodetic studies of the site.
Selection of workers and quality control of construction.
Construction work specified in the contract (from the zero cycle with laying the foundation to the laying of utilities and finishing).
Video description
Today we will discuss how to build a house inexpensively from aerated concrete. How much does a turnkey aerated concrete house cost in the following video:
Of course, you will be able to receive a report at any time or personally control how the construction is going and how the agreed estimate is being spent.
Country house made of aerated concrete blocks, individual project Source bankfs.ru
When choosing a construction company, you should focus on the time of its existence, the number and quality of completed projects, and reviews of real customers. Companies with extensive experience have their own design office, permanent suppliers and professional work teams of various profiles. Building companies that care about their reputation operate according to a well-established scheme, prefer to maintain optimal prices and often have a system of discounts on materials.
Prices for the construction of country houses from gas blocks in the Moscow region are as follows:
area up to 100 m²: an average of 2.25 - 3.700 million rubles.
From 100 to 200 m²: 4.150 - 5.200 million rubles
From 200 to 300 m²: 5.560 - 8.670 million rubles
