Lightweight

concrete
utilizing in
excess of 25%
of fly-ash
Affordable houses cast in-situ in Indonesia in density 1.200 kg/m³ and wall-
Neopor cellular lightweight concrete (CLC) has been thickness of only 60 mm. One house each day per each mold. Frames for
used in over 40 countries over the past 25 years to pro - openings (d/w) and facility tubes cast-in.
duce over hundred thousand houses and apartments,
also schools, hospitals, industrial and commercial buil -
dings.
CLC is an air-cured lightweight concrete that can be
produced at project site, utilizing equipment and molds
normally in use for conventional concrete.
The density recommended is 1.000 kg /m³ (oven-dried) for
blocks and 1.200 kg/m3 to produce prefab elements and
walls cast in-situ. The typical mix for a 1.000 kg/m³ density
CLC to be used in blocks is as follows (to produce
1 m3)
Cement (Portland): 190 kg = 61 liters
Sand (0 - 2 mm or finer): 430 kg = 164 liters
Fly-Ash: 309 kg = 100 liters (approx)
Water: 250 kg = 250 liters
Foam (neopor-600): 423 liters
Wet density 1.179 kg/m3
Total volume
(submerged in water) 1.000 liters (= 1 m³)
Expected (oven-dry)
density. approx. 1.000 kg/m3
Content of air
Light-weight block-production on site in India. Specially designed molds
in concrete approx. 43% produced locally to Neopors specifications are assembled and waxed and
Content of Fly-Ash in poured with CLC density 1.000 kg/m3.
solid material (929 kg): 33%
Content of Fly-Ash in
oven-dry material: 31 %

Benefits of CLC blocks/elements

- Tremendous weight reduction
- High thermal insulation
- Optimum fire rating
- Substantial material savings:
- no gravel used
- little cement
- less steel in structure and
foundation
- Easy and fast production
- No primary energy and
reduced transportation
costs
- Boon for remote areas
Demolding of blocks the day after casting or earlier it accelerated by
with only sand available either steam, heat or chemicals.
CLC, like conventional concrete ages well, increasing its
strength by as much as 50% (!) between 28 and 90 days
after pouring, As long as CLC draws humidity from the
atmosphere it will keep on increasing its mechanical
properties.
Only 1 kg (1 Itr) of Neopor-600 foaming agent is essen tial
to produce 1 m3 of CLC for instance in a density of 1.200
kg/m3: A 200 kg/liter drum of Neopor lasts for more then
200 m 3 of CLC. Neopor has a shelf -life of minimum 24
months.
Molds or design to produce inexpensive molds locally
are provided by Neopor. Shape and size of blocks are given by the molds. Blocks are sprinkled
with water. Production and curing on the construction site to save
transport and multiple handling.

Costing

Neopor customers undertook extensive co sting in different countries to

evaluate competitiveness against conventional concrete blocks, clay -
bricks and autoclaved aerated blocks on the finished wall. In particular if
fly-ash is utilized, blocks of CLC often turn out to be the most competitive
ones, also due to little equipment required (no block -making plant) can be
produced on the site, saving transport and multi -handling.
In view of fly-ash - an enviroment pollutant industrial waste - being a ma-
jor ingredient of CLC, and this being a good subst itute for ordinary clay
bricks (which use high primary ENERGY and precious agricultural top -
soil), the Government of India for instance has given special Import duty
concessions.
CLC is an excellent and competitive material for low -rise, load-bearing
construction and outside walls aswell as partitioning work in multi -storey-
ed blocks.

Popular block sizes are:

600x200x200/100mm
500x250x200/100mm
500x400x100mm
or as desired

Blocks are cast in vertical position to offer equally accurate sides, given
by the mold. Only one side (the top when cast) is not given by the mold
as open-top, which is screeded. This side will face the next block in
masonary anyhow.
Blocks are used for outside walls and partitions
on highrise structure of conventional concrete.

Curing of CLC takes place within the same period as

conventional concrete. If ca st in the evening, the con -
crete can be demolded next morning. Curing can be
speeded up by either heat, steam or chemical (accelera -
tors). - As in conventional concrete CLC may also be
coloured (adding pigments).

Substantial weight reduction in high-rise by using CLC for multiple

purpose (walls, floor screeds, balco ny rails, bath rooms etc) saving
tremendous quantities of steel in foundation.