Construction of monolithic houses from fiber foam concrete. Design of houses made of fiber foam concrete Design of a monolithic floor slab made of fiber foam concrete

Fiber foam concrete blocks (FPB) are by far the most effective material for external 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 flammable, since it is a stone product.
ALF-B line for the production of fiber foam concrete blocks

The main advantage of using blocks during construction is the reduction of construction time since blocks gain strength in production. Factory production allows us to achieve high quality and consistent block properties. It is also important that small-piece technology allows the construction of buildings with a free layout and varied architecture.
Sarmat Group's advanced equipment for the production of fiber foam concrete blocks makes it possible to avoid pouring into molds and cut on sawing machines with an accuracy of 1-2 mm, ensuring 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 from Fokon allows us to reduce costs and ensure high and stable quality of 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 department, which reduces inventory as starting 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 fillers, foaming agent and water. To give the material higher quality indicators, polyamide, polypropylene or basalt fiber is used.
The mixture is prepared in separate room– Mixture preparation module (Fig. 1). The process of manufacturing the FPB mixture occurs automatically.

Rice. 1 The Module contains a mixture preparation control unit BUSM, which controls the process of obtaining fiber foam concrete, and can also store recipes, display the status of the main components of the Module and prepare information for accounting. The process of transporting and loading components occurs automatically. The capacity of the bunkers is designed for 3-6 hours of operation. The module is serviced by 1 worker-operator. Next, the mixture from the Module is supplied to the position of pouring the mass (into the mold), where the 2nd worker is located. The filling position is the point where the filling module docks with the automated sawing complex (APS) 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 carts move along rails. After 5-8 hours, the finished array appears at the agro-industrial complex cutting position.
Photo of the saw complex in Dubna At the agro-industrial complex, allowances are cut off on all sides with saws and the specified block size is obtained. Ready blocks automatically placed on a 1200x1000 pallet. The agro-industrial complex is controlled by 1 worker-operator. The fourth worker installs pallets and packages products. The forklift driver is the 5th worker.
The responsibilities of the master technologist include quality control of FPB blocks at all stages, selection of the necessary recipes, control of equipment washing, 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 removal and block palletizing systems are available as separate options.
• To reduce warehouse costs, it is recommended to additionally install a “drying” line, after which the blocks can be immediately (after 24-30 hours) sent to the customer.

The produced FPB lines are designed on a modular basis; their performance can be set depending on the needs of the market in each specific case. The lines are designed for continuous operation in 3 shifts. Payback of the line is from 13 months.
For a floor of a house with an area of ​​600 m2, an average of 70 m3 of blocks will be required for external walls and more than 100 m3 for internal walls, i.e. for a 17-storey building with 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 (right).

But they have one thing weakness: When the wall shrinks or defrost cycles increase, cracks may form 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. The foamy structure of the raw 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, to build a two-story house.

The idea of ​​increasing 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 greater internal conjugation, due to the uniform introduction of dispersed reinforcement into the mixture (0.5-2%) use different types fibers or granules:

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

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

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

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

What does reinforcement of foam blocks provide?

1. Bend tensile strength is 25% higher.
2. Impact resistance is 9 times higher.
3. Increase in density as the ratio of mass to volume - up to 1,200.
4. Thermal insulation qualities are 30% higher.
5. Blocked capillaries reduce water permeability.
6. Fire resistance increases, allowing destruction of an object made of reinforced blocks only after 14 hours.
7. Frost resistance increases by 1.5 times (up to 100 cycles).
8. Sound insulation performance increases.
9. Increased strength to local loads expands the scope of application of fiber foam blocks, including multi-story construction.
10. The increased strength of the blocks makes it possible to reduce their dimensions and, thereby, reduce the cost of transportation (there are 28 blocks or 56 half-blocks in 1 cubic meter).

Technical characteristics of fiber foam concrete blocks

They're not very differs significantly 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);
• shrinkage upon drying (no more than 0.7 mm/m);
• block weight - 13-27 kg;
• dimensions: 20x30x60 and 10x30x60.

Similarities with foam block

1. Both types of building blocks have the same production technology, which is regulated by the same GOST 21529-89.
2. They do not require major 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 fiber loses 20% of its strength when cut).
4. Both types are characterized by lightness and durability.
5. They are fire resistant.
6. They retain heat well in the room.
7. They are pliable machining milling cutter, perforator, strober.
8. For masonry work on both types of material, special glue is used.
9. Have general use according to density indicator:

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

Have identical in appearance and purpose masonry units:

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

Non-standard products (of the required density and dimensions) are produced to order from the consumer.

Where is it preferable to use fiber foam block?

• Construction of industrial buildings, garages and domestic buildings;
• construction of low-rise buildings using a frameless method;
• construction of attics, dachas, cottages;
• during reconstruction of buildings;
• for the installation of inter-apartment and interior partitions;
• for lintels over window and door openings;
• for the installation of formwork for a monolithic belt;
• for transverse ligation of masonry;
• construction of buildings of any number of storeys on a reinforced concrete frame.

The advantages of fiber foam concrete acquired during the reinforcement process

1. The fiber frame distributes the load throughout the entire volume of the wall blocks.
2. Due to the ideal geometry of the blocks, smooth walls can be erected.
3. Has resistance to high humidity. Does not get wet even when in contact with water.
4. Allows installation of communications (pipes, electrical networks), both open and hidden.
5. Holds heavy objects (pictures, cabinets, shelves) well to the wall.
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 walls (compared to brick) by 3 times.
8. Reduces costs for building materials by 4 times.

Construction company "SK-Absolute" provides a full range of services from design to construction of houses and cottages using technology monolithic construction made of fiber foam concrete.

When constructing facilities, we use the most modern equipment to ensure high-quality work.

Technology does not require use lifting mechanisms, allows you to reduce construction time, implement architectural solutions of any complexity.

The main material for construction is fiber foam concrete - foam concrete with the addition of polypropylene fibers.

Houses made of fiber foam concrete are equally good in both cold and hot climates. Characterized by low thermal conductivity and being vapor permeable, they provide comfortable living. Due to natural ventilation The house has a healthy, pleasant microclimate. The materials used are non-flammable, environmentally friendly, and excellent sound insulators.

What are the advantages of fiber foam concrete?

• Reliability

Fiber foam concrete is an almost eternal material, not subject to the effects of time, does not rot, and has the strength of stone. Increased compressive strength allows the use of products with lower volumetric weight in construction, which further increases the thermal resistance of the wall.

• Heat

Thanks to the high thermal resistance, buildings made of fiber foam concrete are able to accumulate heat, which during operation can reduce heating costs by 20–30%. High geometric accuracy of product dimensions allows you to avoid “cold bridges” in the wall and significantly reduce the thickness of the internal and external plaster. The weight of fiber foam concrete is 10% to 87% less than standard heavy concrete. Significant weight reduction results in significant savings on foundations. In the diagram on the right you can see a comparison of the thicknesses of single-layer enclosing walls according to SNiP-N-3-79 and SP 41-99.

• Microclimate

Fiber foam concrete prevents significant heat loss in winter and is not afraid of dampness. The pores of fiber foam concrete, unlike aerated concrete, are closed, this allows you to avoid too much high temperatures in summer and regulate the air humidity in the room by absorbing and releasing moisture, thereby helping to create a favorable microclimate.

• High installation speed

The house is installed without the use of lifting equipment due to the lightness of the structural parts and unique mobile equipment for pouring fiber foam concrete. The work does not require a lot of time and labor - a two-story cottage structure can be assembled by a team of six workers in 10-12 days.

• Soundproofing

Fiber foam concrete has a relatively high ability to absorb sound. In buildings made of cellular concrete, the current requirements for sound insulation are met.

• Environmental friendliness

During operation, foam concrete does not emit toxic substances and is second only to wood in its environmental friendliness. For comparison: the environmental friendliness factor of cellular concrete is 2; wood - 1; bricks - 10; expanded clay blocks - 20.

• Economical

Fiber foam block has a high geometric dimensional accuracy of products (+1mm) and can significantly reduce the thickness of internal and external plaster, as well as total consumption masonry mixture. The weight of foam concrete is 10% to 87% less than standard heavy concrete and brick, so there is no need to make powerful and expensive foundations.

• Fire safety

Products made of fiber foam concrete correspond to the first degree of fire resistance; when exposed to open fire, they do not lose strength and do not emit harmful substances. The Ministry of Emergency Situations is recommended for fire walls, including those at storage facilities for highly flammable materials.

• Transportation

The ratio of weight, volume and packaging does everything building construction convenient for transportation and allow full use of transport capacity.

• Wide range of applications

In addition to walls, fiber foam concrete is used for heat and sound insulation of roofs, floors, insulation of pipes, production of prefabricated blocks and partition panels, floors and foundations.

The manufacturing enterprise BAZA SM LLC 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 10/11/2013).

At low specific gravity(on average 3 times smaller brick) fiber foam concrete has strength sufficient for the construction of cottages with load-bearing walls up to 3 floors.

It has good heat and sound insulation properties. 200mm of fiber foam concrete with a density of 600 kg/m 3 is equivalent in thermal and sound insulation to approximately 1000mm brickwork. Houses built from fiber foam concrete are not cold in winter and not hot in summer.

Fiber foam concrete is a fire-resistant material, as evidenced by the fire certificate and fire resistance tests of wall structures (Fire certificate for products made of fiber foam concrete No. NSOPB.RU.PR014.N.00091 dated March 19, 2014).

Fiber foam concrete can be easily sawed with a hacksaw. Construction stores offer a hacksaw for foam concrete with pobedit tips.

By introducing fibers into the composition of foam concrete, a more closed pore structure is formed, thermal insulation, sound insulation 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 existing ones. wall materials, the durability of the material increases,
• Impact strength increases, fragility decreases, the material becomes possible to transport over any distance by any means of transport,
• the tensile strength of the material during bending increases, which makes it possible to manufacture products of complex configurations,
• increases significantly resistivity pulling out self-tapping screws.

FIBROFOAM 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"
Thermal insulation
		B1; B0.75; B0.5
Structural and thermal insulation		B1.5; B1 ;B0.75
		B5; B3.5; B2.5; B2

Energy efficiency table for fiber foam concrete and aerated concrete

	Indicator name	Aerated concrete D500	Fiber foam concreteD500	Note
		GOST 31359-2007	TU 5741-001-80392712-2013
	Thermal conductivity coefficient of the material in a dry state, W/m °C			The performance of fiber foam concrete is 30% better
	Thermal conductivity coefficient of the material under conditions “A”*, W/m °C
	Thermal conductivity coefficient at equilibrium weight humidity 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 GOST 31359-2007 “AUTOCLAVE CURING CELLULAR CONCRETE”

Comparative characteristics of fiber foam concrete

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

Indicators	wall of ceramic bricks(voids - 13%, density 1600 kg/m 3	Ceramic wall solid brick(density 1800 kg/m 3) with insulation	Permanent formwork made of expanded polystyrene and reinforced concrete with a density of 2500 kg/m 3	wall of aerated concrete blocks density D500 kg/m 3	Wall made of fiber foam concrete blocks from BAZA SM LLC with a density of D500 kg/m 3
Wall thickness, m	1,29	0,46	0,25	0,40	0,30
Thermal conductivity coefficient of wall materials under conditions “A”, W/m°C	0,58*	0,041 / 0,7*	0,041 / 1,92*	0,141**	0,111***
Frost resistance of external wall material, cycles	35	35	--	35	75
Weight of 1m 2 walls, kg	2370	800	375	270	200
Cost of 1 m 2 walls, taking into account materials and work on constructing 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 CURING CELLULAR CONCRETE”
*** - data according to TU 5741-001-80392712-2013 “NON-AUTOCLAVE CURING FIBROFOAM CONCRETE PRODUCTS”
**** - the cost of 1 m2 of ceramic brick walls is calculated based on the condition of using only backfill bricks

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 disadvantages; monolithic fiber foam concrete, due to its components, is a fragile material, which means its production technology is different and requires increased effort. When mixing the components correctly, 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 their light weight. And:

Advantages

The advantages of fiber foam concrete significantly 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 block production.

Used for the production of fiber foam concrete block:

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

Before you start working with blocks based on foam concrete with the addition of fiber, you need to read the recommendations experienced builders. When doing the work yourself, you need to remember that the blocks contain components that are highly absorbent. This means that the solution needs to be prepared with a liquid consistency.

It is recommended that products made from blocks based on fiber foam concrete should not be left without appropriate finishing. After all, they are capable of decorating 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 manufacturing plant. Therefore, when ordering blocks, you need to clarify their dimensions in advance. The packaging of the goods must not be damaged, and the contents must correspond to the order.

It is recommended to fix blocks based on foam concrete with the inclusion of fiber using nails and dowels with anti-corrosion coating for light loads, as well as special dowels that are recommended by the fastener manufacturer for cellular block under heavy loads.