Company Portrait

NEOPOR System GmbH has been on the world-wide market with CLC (Cellular
Lightweight Concrete) for more than 30 years and responsible for the construction of
well over 300.000 apartments and houses, as well as schools, hospitals and commercial
buildings in over 50 different countries, utilizing NEOPOR equipment, foaming agent,
fibres and of course NEOPOR technology.
Buildings cast up to 25 years ago are evidence for the well ageing of CLC, using the
same "ingredients" as in conventional concrete, namely sand, cement and water (gravel is
large sand) and air, responsible for thermal insulation and weight reduction, embedded in
our foam, which solely serves as wrapping medium and has no chemical reaction.
Therefore CLC on its achievable level offers the same behaviour as convention concrete.
As long as exposed to humidity in the atmosphere it will increase its mechanical
properties (e.g. strength) infinitely.
Using only sand, CLC preserves natural resources such as gravel and clay, both running
short in many parts of the world and as in the case of clay even being prohibited from use
for building components in an increasing number of countries (e.g. China) already.
Natural resources are also preserved substantially by the high insulation properties of
CLC, considering that it offers 500 % (!) and more insulation than conventional concrete.
Whilst in cold countries insulation serves primarily against cold weather, protecting
against heat (air-conditioning) requires another 500% more primary energy to cool down
- certainly a large bill for any ones budget.
NEOPOR CLC
Cellular Lightweight Concrete (CLC) is conventional concrete, where natural aggregate
(gravel) is exchanged for the best insulation medium available, namely air, embedded in
an organic and bio-degradable foam that offeres no chemical reaction but solely serves as
wrapping material for the air. Consequently CLC behaves, like conventional concrete, in
particular concerning curing, hardening and most important "ageing ". CLC infinitely
increases its strength by hydration (forming of crystals in cement) as long as exposed to
humidity in the atmosphere.
For structural (steel-reinforced) application, CLC is used in densities of 1.200 to 1.400
kg/m, which, due to the billion of microsized and uniform air bubbles offer 500 % (!)
more thermal insulation and a substantialy higher fire-rating than conventional concrete.
If a wall of conventional concrete should offer the same thermal insulation as CLC, the
wall produced would have to measure 5 times thicker and therefore also use 10 times
more material (sand, gravel, cement) to produce. In hot environment the essential airconditioning requires 500% (!) more primary energy to cool down than when heating, a
fact, which is not even known to many experts.

Lightweight concrete utilizing in excess of 25% of fly-ash

Neopor cellular lightweight concrete (CLC) has been used in over 40 countries over the
past 25 years to produce over hundred thousand houses and apartments, also schools,
hospitals, industrial and commercial buildings.
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 /m (oven-dried) for blocks and 1.200 kg/m to
produce prefab elements and walls cast in-situ. The typical mix for a 1.000 kg/m density
CLC to be used in blocks is as follows (to produce 1 m)
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/m
Total volume (submerged in water) 1.000 liters (= 1 m)
Expected (oven-dry) density. approx. 1.000 kg/m
Content of air in concrete approx. 43%
Content of Fly-Ash in 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 with only sand available

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 m of CLC for
instance in a density of 1.200 kg/m: A 200 kg/liter drum of Neopor lasts for more then
200 m of CLC. Neopor has a shelf -life of minimum 24 months.

Molds or design to produce inexpensive molds locally are provided by Neopor.

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 environment pollutant industrial waste - being a major ingredient
of CLC, and this being a good substitute 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 as well as partitioning work in multi -storied 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.
Curing of CLC takes place within the same period as conventional concrete. If cast in the
evening, the concrete 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).

Affordable houses cast in-situ in Indonesia in density 1.200 kg/m and wall thickness of
only 60 mm. One house each day per each mold. Frames for openings (d/w) and facility
tubes cast-in.

Light-weight block-production on site in India. Specially designed molds produced

locally to Neopors specifications are assembled and waxed and poured with CLC density
1.000 kg/m.

Demolding of blocks the day after casting or earlier it accelerated by either steam, heat or
chemicals.

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.

Blocks are used for outside walls and partitions on highrise structure of conventional
concrete.

Substantial weight reduction in high-rise by using CLC for multiple purpose (walls, floor
screeds, balcony rails, bath rooms etc) saving tremendous quantities of steel in
foundation.

Benefits of NEOPOR CLC

Compared with conventional concrete, Cellular Lightweight Concrete (CLC) has many
benefits.
The tremendous savings described when using CLC are manifold, continuing with
substantial savings in raw material (no gravel required), in dead load of high-rise
reducing by almost half. Considering that a substantial amount of steel is necessary only
to carry the weight of the structure, steel requirement might reduce by hundres of ton in
high rise.
Weight reduction is obvious in transport, where almost double of volume of building
material can be produced, it has an impact on craning, where either larger panles can be
taken, or the full capacity in span. Alternatively less re-location of the crane is necessary.

Thermal Insulation increasingly turns to be the most important issue in the planning and
construction of buildings. There are many costly ways of insulation on sandwich
structure of a wall, adding the one or another rigid insulation material, with a satisfactory
result by computation but not always a sound solution in safety, health or environment.
The best solution is, to incorporate thermal insulation in the mix of a concrete, such
offered in air cured CLC.
The air-embedded in the CLC is also instrumental for the high fire-rating. In 1200 kg/m
density a 13-14 cm thick wall has a fire endurance of 5 hours. The same delay occurs
with a 400 kg/m layer of CLC in only 10 cm thickness. CLC is otherwise noncombustible.
Over the efforts to keep on increasing the thermal capacity of building members, other
aspects have been neglected, such as sound insulation. Sound is experienced as air-borne
or foot-fall sound (impact). Air-borne it is a rule of density and therefore CLC offers
superior protection than very light concrete (ACC). In impact sound it is superior to
conventional concrete. Hitting a wall with a hammer, will let you feel the full force on the
other side, whilst the air embedded in CLC will not allow the blow to pass through. At
the most it will suffer a small dent and thereby prevent any greater damage.
As the impact force will not transmit, slabs produced of CLC or topped with a layer of
CLC floor screed will prevent any sound being noticed in the room below. Walls of CLC
will also serve as sound retaining walls on roads or railway tracks therefore, absorbing
the sound and preventing it from bouncing to the other side.
Adding fibers to CLC is a further important benefit, increasing bending stress
substantially and most of it impact strength. The three dimensional acting fiber (e.g.
polypropylene) will further reduce shrinkage, therefore reducing water absorption and
increasing strength (up to 25 %. This is appreciated most when producing slender
building components.
Using only sand, cement, water and foam, the cost for one m of CLC in most cases is
less even than for the equivalent volume of conventional concrete. Adding all the
described highly appreciated benefits (comprising CLC) to regular concrete, if at all
possible, the cost for such regular concrete would probably double but still not reach the
overall quality of CLC.
Our system can be readily integrated into existing concrete and prefab works, by just
installing the inexpensive, simple but fully automatic foam generator. Over 300.000
buildings have been completed in the past 30 years in over 50 different countries, either
using blocks of CLC, steel-reinforced prefab and slabs but mostly casting complete
houses in one pour, using vertical formwork. This way one building is completed each
day with every set of moulds, frames for doors and windows - or openings therefore,
cast-in, the same as facility pipes/tubes for power and sanitary.

CLC becomes increasingly popular also in such countries, where the use of clay will be
prohibited to conserve is for the agricultural industry only. A starter-kit is available for
less than 10.000 Euro ex works.
Required Equipment

MFG / MFG-A Foam Generator

Conventional Mixers, pan-mixer, truck-mixer
Conventional conveying system (buckets, Concrete pumps etc)
Conventional moulds, horizontal/vertical

Raw Material

Sand -2, -4, -6, -8 mm, depending on density and availability

Preference

Washed River Sand

min. 20% fines
Cement, Preference Portland
Water for Foam production: Potable
Foaming Agent: Neopor-600/700

Optional

Neofibre: Polypropylene
Fly-ash up to 40% on total mix
Lightweight Aggregate (e.g. expanded clay etc.)

Production Procedure
Sand: Optimum properties are achieved when selecting the most suitable raw material
(Sand,Cement). Preference : River (round) sand, washed and with minimum 20% fines.
Dust in sand increases the demand for water and cement, without adding to the
properties. It also increases shrinkage. A certain, small amount (20%) of fines contributes
towards strength. As in conventional concrete (CC), the sand should be free of organic
material or other impurities. Crushed sand, due to sharp edges may destroy the foam
mechanically.
Cement: Portland cement is preferred over other cements, such as pozzolan. For Early
stripping and optimum mechanical properties, high- grade (early strength) cement is
recommended. Thick walls and when using battery-moulds, excess heat is developing
within and might therefore ask for a lesser grade of cement. Remember : The slower the
hardening, the better the final quality of concrete. Where economical, fly-ash may be
added to the mix to substitute some of the cement. Fly-ash normally will retard hardening
though.

Water: When used to produce foam, has to be potable and for best performance should
not exceed 25C. Under no circumstances must the foaming agent be brought in contact
with any oil, fat, chemical or other material that might harm its function (Oil has an
influence on the surface-tension of water). The oil/wax used in moulds will not harm,
since the foam by then will be embedded in mortar. Water to prepare the mix has to
conform with general requirements for concrete
Foaming Agent: The containments holding foaming agent must be kept air-tight and
under temperatures not exceeding 25C. This way the shelf-life is guaranteed for 24
months from date of Invoice. Once diluted in 4o parts of potable water, the emulsion
must be used soonest. (Diluted in 40 parts of water, Neopor 600 foaming agent is used by
many as very effective fertilizer).
Correct density of foam
The weight of the foam should be minimum 80 g/l. Use a containment of as close as
possible to 10 liters in volume, to check the weight (density) of the foam.
Smaller containments might not allow to pour foam into, without possible large voids. A
fast check on the correct weight is also possible by turning the bucket with foam up-side
down. If the weight of the foam is minimum 80 g/l and does not drop out of the bucket,
the consistency of the foam is correct. After several weeks of experience the person in
charge of producing foam will know the correct quality of the foam by sight. Once set
correctly, the foam generator will keep the consistency stable, as long as air-and watersupply remains constant as well. We still recommend to check the weight of the foam
once in a week or if the density/consistency of the mix varies.
Preparation of moulds
For smooth surfaces clean moulds completely of remaining concrete, the steel/or wood
surface must be oiled/waxed. Preference : Organic or vegetable oil/wax. Trials with
different materials will have to show best results. Oil or wax will not destroy the mix,
once the foam has been mixed in the mortar.
Steel reinforcement will be placed in the moulds as usual. No coating of the steel is
necessary as in AAC (Syporex etc.)In panels of more than 12-15 cm thickness, we
recommend the use of a double mesh (100 x 100 or 150 x 150 mm). The steel connected
to the lifting anchors should reach more then half of the width of the panel and should
possibly not be connected to the mesh. Ordinary steel is used as in CC when casting
densities of 1200 or higher. The high ratio of cement to material in CLC ensures proper
protection of the steel against corrosion.
The steel embedded has to be covered by minimum 25 mm of concrete The use of
spacers is recommended. To prevent cracking when lifting/tilting, steel rods may be
placed across the anchors. A triangular strip of plastic or wood might be inserted along

the bottom edge of the mould better also along the top, to prevent sharp edges, that
might break of when handling and give the panels a poor appearance.
Charging, Mixing and Pouring
Before charging the mixer with material, it must be rinsed, in particular if the concrete
produced before, used any additive, which might have adverse reaction on the foam.
Where possible, start the mixer before charging it with material. If the sand contains
excessive amount of water, the weight has to be adjusted, adding that much more sand as
it contains water by weight, reducing at the same time the amount of water to be added to
the mix. To obtain optimum performance, sand is first fed into the mixer, first absorbing
water left after rinsing or from the previous (CLC-) mix.
This way, the cement to follow will not clod, allowing best possible distribution in the
sand. Keep on mixing, until a homogenous colour of the mix is achieved. If using
Neopor-fibre, this is the moment it has to be added, mixing approx. 1 min. for each kg
added, to allow the fibrillated polypropylene fibre to open-up.
Check Neopors Recommended Mix Design for the recommended configuration of
material to be used in different densities. The densities referred there-under are oven dry,
achieved when drying the mix for 24h at 105C. Before adding foam, the water/ cement
(w/c) ratio of the mortar must be minimum 0,35. Lower ratios may cause the cement to
draw water from the foam, causing it to partly or totally collapse, increasing the density
and decreasing the yield. This is one of the most likely mistakes when learning how to
produce CLC. Therefore, if one is in doubt, one should always add more, rather than less
water. To a certain extend this might even increase initial strength. Doing the same with
CC would definitely reduce strength, as excessive water causes voids when evaporating .
CLC on the other hand consists of voids only. The weight of the foam should be
minimum 80 g/l. Use a containment of as close as possible to 10 liters in volume, to
check the weight (density) regularly.
Smaller containments might not allow pouring foam into, without possible large voids. A
fast check on the correct weight is also possible by turning the bucket with foam up-side
down. If the weight of the foam is minimum 80 g/l and does not drop out of the bucket,
the consistency of the foam is correct. After several weeks of experience, the person in
charge of producing foam will know the correct quality of the foam by sight.
Once set correctly, the foam generator will keep the consistency stable, as long as air-and
water-supply remains constant as well. We still recommend to check the weight of the
foam once in a week or if the density/consistency of the mix varies.
Gravity mixers (e.g. Ready Mix) take the foam under almost instantly and distribute it
homogenously in the mix. It takes more time to achieve a proper distribution when using
pan-mixers or similar. In between pours, the mixer should be kept in motion until it is
completely discharged.

CLC always should be poured in the shortest possible time. If buckets are used to fill
moulds, they should hold as much CLC as possible, possibly even pouring one complete
panel in one step. Extended time between pours of one building member might result in
the creation of dry-joints as happening in the case with regular concrete as well.
Although CLC does not require vibration - at least not to densify the mix - which is liquid
anyhow, vibration of horizontally produced panels will show an even better surface,
drawing cement slurry to the mould side. Preference is given to High-Frequency
vibrators. Length of vibration 15-20 sec. or until bubbles on the surface appear in large
numbers. Use aluminium or other straight and sharp-edged screedslats immediately after
pouring the concrete. Delayed screeding might smear the surface. If moulds have to be
moved after screeding, this might have to be repeated. Any disturbance of the freshly
poured CLC during the setting process, might be harmful and cause part of it to collapse,
in particular when the concrete is not hard enough yet to carry the weight and the foam
has been weakened by loss of water, drawn by the cement already for setting.
The poured building member should be covered, if possible, with a canvass or plastic
sheet to keep the evaporating water on the surface. As with CC, hardening may be
accelerated either by heating the moulds, steam or chemical (ask for details). Using most
standard types of cement, panels may be lifted the day after casting. Due to the reduced
strength in CLC, moulds should be tilted before lifting the panels. For the same reason
panels of CLC should be handled with utmost care to avoid damage.
Curing / Transport / Assembly
Panels should be positioned upwards on the curing yard, resting on a soft underground best on a rake or wooden beams. All possible efforts should be taken, in particular in dry
and hot climate or more even when windy, to keep the panels damp for at least three,
bettor for more days. A sprinkler will be helpful or canvas that is kept wet. Curing
compound would be the costly alternative. Standards call for a 24 day curing period for
cement-based building members.
Remember: Cement/Concrete only hardens with water or in a humid environment
Due to reduced weight, more volume of CLC building elements can be transported at the
same (increased pay-load) then of CC. Panels should be kept upright during transport and
also on a soft/wooden underground. Unload only in tilted position.
Assembly
Assembly of panels in CLC happens usually the same way as with CC. Special care has
to be taken not to apply any mechanical force to avoid damage. If necessary, panels of
CLC may be sawn (no gravel), definitely nailed (without the use of dowels as in AAC),
drilled or profiled. In densities of 1200 kg/m and higher, where reinforcement is used,
CLC requires no special coating/plaster on the outside. Water-repellent paint (dispersionpaint) will be suitable.

Vertical casting
The high fluidity of CLC allows full height walls or complete houses (floor by floor) to
be cast in one pour, inclusive the slab. Frames for voids for windows, doors and other
opening, or penings therefore are cast in place, together with empty tubes and pipes for
power and sanitary. No voids, no sagging (beneath frames). Walls/ partitions may be as
slender as 50 mm thick only (!) as no vibration is necessary. With a coarse sand paper
stuck to a piece of board, rub the walls immediately after stripping, in circular motion, to
eliminate possibly honey-web or noses caused by possible irregularities in the mould or
by joints. Perhaps a day after stripping it is recommended to saw imitation joints from
both sides of the walls on neuralgic positions to allow possible shrinkage to accumulate
in the joints and not show on the walls, as also done in CC when casting in situ.
Detailed drawings - according ICBO - upon request. As with all lightweight concretes
(lesser with CC) hair-cracks might appear but have no adverse effect on the
reintorcement, and usually disappear when painted. This way one complete house is cast
each day with every set of vertical mould. Where applicable even the gable can be cast at
the same time with appropriate modification to the mould (see attched photograph of a
sample house by the largest manufacturer of cement in Africa PPC)
Guidelines
BRIEF GUIDELINES FOR MANUFACTURING, MASONING CLC BLOCKS AND
MEASURES SUGGESTED TO AVOID & REPAIR CRACKS IN MASONRY
(Kindly refer provisions of relevant clauses of IS: 6042 &IS:2572 for details)
1.0 Manufacture, Curing & Maturing of CLC Blocks
1.1 CLC slurry must be made using quality input raw materials {Portland Cement Grade
53, Clean river sand, Grade 1 Fly Ash, Clean water and Neopor Foam density 80
gms/litre} in defined proportions, mixed in a gravity mixer and poured into leak-proof
battery moulds.
1.2 Blocks de-moulded on hardening are stacked, water spray cured for about two weeks
like any other concrete product and then allowed to mature and get thoroughly dried till
completion of 4-weeks after casting to enable their initial shrinkage to get completed,
before being allowed to be used in masonry work.
2.0. Masonry Work & Plaster
(a) Masonry mortar should be leaner than the strength of block. As per provisions of
Table-1 of IS: 2572; preferably 1-Cement, 1-Lime & 6-Sand. If Cement Sand mortar 1:6
is used then partial substitution of cement be done with Fly ash.
(b) The blocks should be laid dry, but the surface on which mortar is being laid should be
moistened to obviate it absorbing water from the mortar.

(c) Both horizontal and vertical joints should be ~ 10 mm thick.

(d) The mortar shall be well spread on both horizontal and vertical surfaces of the joints
to produce fully filled-up and well compacted joints. It may be necessary to add mortar
especially to vertical joints to ensure that they are well filled.
(e) The mortar shall be racked out of joints with a trowel to a depth of about 10mm as
each course is laid to ensure good bond for plaster.
(f) When the mortar has stiffened somewhat, it shall be firmly compacted with a jointing
tool. The mortar shall be pressed against the units to affect intimate contact between the
mortar and the masonry to obtain a water tight joint. Please refer two attachments
reproduced from one of the referred IS codes.
(g) Weldmesh ladder of 75mm width of 3 or 4mm mesh of 25x75 mm rods be placed
in every third course of 100mm thick partition walls.
(h) Masonry shall be cured for at least 7-days and then allowed to dry before applying
rendering over it.
(i) Rendering of walls may be done with 1:1:6 Cement, lime, sand mortar or 1:4 cement
mortar. When smooth finish is desired internally 2-3 mm thick lime neeru finish may be
applied.
(j) The masonry walls, abutting against structural elements like columns, beams may
deflect, move because of load, settlement, shrinkage or thermal effects. In order to avoid
cracking as a result of such movements, a slip joint shall be provided, preferably packed
with a resilient material. (This could be material like Sika Flex Construction, Dr. Fixit
Crack-X etc.)
If, however, no joint line is desired to be seen at the junction of columns and beams with
masonry from aesthetic considerations, then the junction, as treated above may be over
laid with a 200mm wide chicken mesh, equally spaced on either side of the joint line,
before rendering the wall with plaster.
3.0 Observation of cracks and Remedial Measures
It is felt that deficiencies in observance of broad stipulations stated under 1.2, 2(a) to 2(g)
etc. above have resulted in appearance of some cracks at some locations in the plastered
walls. The types of cracks seen are: 3.1 Hair cracks in Putty finish: Some hair cracks have been observed at isolated locations in the putty finish. We concur
with the assessment of your Chief Project Manager, that these are only in the putty layer

and do not extent into the plaster.

(It is likely that if use of cement based putty or Neeru finish is adopted, such a situation
may not occur).
However in the current situation, it is suggested that the joint be cleaned of dust,
removing any flaky material, moisten the surface slightly paint with a brushable
consistency paste of 1 part Sika Latex & 1 part Cement.
Alternatively apply with a putty knife a mix of 2.5 parts Dr. Fixit Crack-X powder mixed
with 1 part water by volume, remove excess material and let it stay for 24 hours before
paining.
3.2 Crack at some masonry junction with Beam/ Column or other locations.
3.2.1 The joint between the structural elements and masonry be treated as stated under
2(j) above. Make a 6x6-8 mm groove along the line of joint with a grinder, clean and
wash with water and fill the groove with Sika Flex Construction or equivalent
polyurethane single compound sealant.
3.2.2 Isolated cracks in the body of the masonry be also opened-up into grooves of 6x6-8
mm with the help of grinder, cleaned and washed and then filled up with a putty made
of :

2-Sika Latex + 5-Cement+ 15 Sand and water over a primer coat, if recommended
by Sika.
or
Dr. Fixit Crack Filler and Water in volumetric proportion 2.5 to 1.
or
1 Bond Aid (of Asian Laboratories, Okhla) :2 parts water mixed with equal
amount of Cement and twice the quantity of Sand.

(Note: A typical sample repair work, noticed at one location, done by some agency by
making 200-250 mm wide repair bands over the crack locations, is un-called for and
would be wastage of costly input materials).
General:

It was learnt that all plaster work is being done using Recron fibre as additive.
However it does not seem to be effective. Use of Polypropylene fibre could be
tried as a better alternative.
Use of any kind of bond aid (to the extent of 2% -3% of cement content) as an
additive in the masonry mortar could improve bonding efficiency and reduce
water requirement for hydration.

Our Assistance

We can render you assistance to: a. Enable you to obtain the first Concessional Duty Certificate from appropriate
Govt. authority for the import of Foaming Generator and the Foaming Agent at
highly concessional custom Duty as per prevailing EXIM policy of Govt. of India.
(Note: The subsequent concession letters for future imports of Foaming Agent
could be obtained by you your-selves based on the experience of the first letter).
b. Guide you in selection of proper quality of fly ash and guiding you with your
initial laboratory trial mixes to arrive at over 25% Fly Ash consumption mixes for
different densities of CLC production.
c. Provide you basic drawing for manufacture of steel battery moulds by your-selves
for the production of pre-cast CLC blocks of desired size and density.
d. Issue guidelines for production of good quality CLC and proper maintenance of
equipment and ensuring quality production and control of CLC with a small
laboratory set-up and daily/ weekly/ monthly control schedule.
&
e. Organize, if so desired by you, deputation of an Indian Specialist for
commissioning of your imported Foam Generator and training of your personnel
in its operation, use, maintenance & quality production of CLC. This could be a
better and more cost-effective alternative to your depending on a foreign expert
from NEOPOR, Germany.
Our fees for the services covered under (a) to (d) above is Rs. 30,000/- only (plus 8%
service Tax), with 50% payable in advance and the remaining amount being paid on your
having been issued the requisite concessional duty certificate from the appropriate
authority.
The commissioning Engineer, if sought by you as per (e) above, shall be reimbursed his
travel costs, provided local hospitality and transport plus Rs. 3,500/- per day for the days
of his absence from New Delhi
Different Methods for producing Blocks of air-cured Cellular Lightweight Concrete
(CLC)
Applicable Standards:
DIN 4232, 4219 Lightweight Concrete
DIN 1048 Testing Methods
DIN 4164, 4165, 4166 ACC/CLC 4223, 4226, 18 152
DIN 4102 Fire Rating
DIN 4108, 52.612 Thermal insulation
DIN 4149 Seismic
DIN 18.152 Solid Blocks
DIN 50.017 Water Condensation
DIN 52.104 Freece-Thaw-Cycle

DIN52.615 Water Vapor Permeab.

DIN 53.420, 50.014 Determ. of Density
For the production of blocks in air-cured cellular concrete Neopor recommends a
mini-mum density of 1.000 kg/m (oven-dry). This is to safeguard that the blocks
produced offer:

Sufficient strength
Affordable shrinkage
Affordable strength
Affordable water absorption

Utmost care has to be taken on the only solid used in CLC (besides binder), namely the
sand. As ruled in general standards for any type of concrete, it has to be free of any contaminationand in sieve according to our attached sample. Generally it is recommen-ded
not to use crushed sand, which tends to crush the foam when agitated (mixed). A special
method of even using crushed sand has been patented and is under trial.
To warrant best distribution of the foam in the shortest possible time, the use of gravity
mixers is recommended, ensuring, that the mix is more than 60% of the total volum of its
total capacity after adding the foam. To ensure optimum strength, it is recommende to
first charge the mixer with sand, until the remaining mix/water left from the previous mix
has been absorbed, before adding cement. When a homogeneous dry mix had been
obtained, the recommended amount of water is been added.
Make sure, that sufficient water had been added, as otherwise the cement in the mix will
draw its shortcomings from the water in the foam, causing the latter to collapse partly or
totally. There is no fear of taking too much water, as the W/C ratio does not play the role
as in conventional concrete, reducing the strength. Too much water in CLC prima-rily
prolongs the hydration process but has no negative reaction on the strength to be
achieved.
Moulds used have to be waxed/oiled befor pouring CLC to allow easy stripping and
smooth surfaces. Care has to be taken in selecting the most suitable wax/oil to allow adhesion of later-on painting or plastering. Where green-strength of CLC is required to
cut larger cakes into desired dimensions, a special tool is available to mechanically determine the suitable time of cutting by wires.
A typical mix design per 1 m of CLC for blocks in density 1.000 kg/m (oven-dry) is
as follows:
Sand up to 1mm, maximum 2 mm : 560 kg
Cement (Portland) : 350 kg
Water in mix : 120 ltrs +
Stable Foam : (560 ltrs)
Water in foam ( use potable water for ~) : 5 ltrs

Wet density : 1.075 kg/m

Oven-dry density : 1.000 kg/m
Acceleration: Hydration/hardening of CLC can be reduced by either using high early
strength cement, warm water (heat, steam) or else chemistry.
Stripping: If not accelerated (see above), the moulds are normally stripped the day after
pouring, cleaned, assembled and waxed/oiled, before pouring again.
Treatment: Curing/herdening after stripping is best done by keeping the blocks moist for
minimum 7 days after, preferably even longer, storing the stripped blocks under canvas,
which is constantly kept moist. It is recommended alternatively, to wrap the stack of
blocks into plastic foil immediately after demoulding ((if possible use shrink foil), to
keep the moist-ure within as long as possible, keeping hydrating /crystallizing/hardening.
Paint/Plaster (Stucco):
When using paint only, we recommend a water repelling quality. Otherwise, different
methos are been applied in different countries. Mortars are prepared in a variety of
qualities as for instance:

Combination mortar of cement plus lime plus sand ( 1 : 1 : 6)

Or else 0,8 parts of cement 0,2 parts of fly-ash plus 6 parts of sand Or else cement plus sand mortar reinforced with say 0,5 kg/m of polypropylene
fibres.

Some also use ladder reinforcement every alternate layer of partition wall masonry.
Others consider it best, if the joint line between the structural frame columns and beams
is defined after plastering work, as this is the location where cracks, if any, appar lateron. The joint under the beam and the top of the masonry wall should prefearably be
sealed with some kind of sealant after the total structural elements are fully loaded with
masonry walls from above (the next floor).
Generally care has to be taken, that the mortar used will develop less strength than the
blocks to be layed on mortar.
Further details are available to our clients upon request.
Range of densities
Density 100 kg/m
NEOPOR offers the only system world-wide to produce a solely mineral-based
insulation board offering the same lambda as man-made polystyrol, poly-urethane or

mineral wool, however without any hazardous behaviour for health, environment or fire.
This density requires autoclaving. Complete plants are available to produce up to 500 m
daily (or more).
Density 300-600 kg/m
This density is primarily applied for thermal insulation or fire protection. It uses only
cement (or little sand), water and foam and can easily be pumped. NEOPOR's foam
generators allow the production of stiff foam for slopes to be applied on roof-tops.
Density 700-800 kg/m
Is also used for void-filling, such as an landscaping (above underground construction), to
fill voids behind archways and refurbishing of damaged sewerage systems. It is also been
used to produce building blocks.
Density 900-1100 kg/m
Serves to foremostly produce blocks and other non-load bearing building elements such
as balcony railings, partitions, parapets and fence walls etc.
Density 1200-1400 kg/m
Are the most commenly densities for prefab and cast in situ walls, load-bearing and nonload-bearing. It is also successfully used for floorscreeds (sound and insulation plus
weight reduction).
Density 1600-1800 kg/m
would be recommended for slabs and other load-bearing building elements where higher
strength is obligatory.

Recommended Mix Designs

Recommended Mix Design to produce 1 m of CLC

Equipment
Minimum investment:
As conventional concrete and prefab plants may be used to produce CLC, the only
investment would be for the inexpensive foam generator and the foaming agent.
Foam generators
NEOPOR System GmbH offers two types of Foam Generators. The BK-8 has an
integrated air compressor. The MFG-A is delivered without an air compressor.

Foaming agent
NEOPOR foaming agent is based on a protein-hydrolisation. It causes no chemical
reaction but serves solely as wrapping material for the air to be encapsuled in the
concrete (mortar). It is bio-degradable and some of the clients even use it as a fertilizer
for plants.

Concrete technology
Raw materials
Mixing and poring
Hydration process
Curing
Treatment

Properties and behaviors

Research & Development (R&D)
Building Technology
why use clc light weight bricks in construction?
for more information:foam generator
Why use clc light weight bricks or foam concrete bricks?
Clc is cellular weight blocks where we can use for load bearing structure
and frame structure .its a other alternative for red brick and fly-ash
bricks.Why
we use clc bricks?
1)Clc is a light weight brick where water absorption is less compare to
redbrick and fly-ash brick
2)High thermal insulation
3)Compressive strength is more than other bricks
4)environmental friendly
5)Quantity of cement is less when making a wall why because
6) clc bricks life span is more than other bricks
Clc block size can make according to our requirements
In India generally block can make
Clc Size per cubic meter
4*8*24

83 clc blocks

6*8*24

55 clc blocks

9*8*24

50 clc blocks

If we take one clc block size red bricks comes around for each clc block
4*8*24
7.1
6*8*24
10.6
How we compare clc bricks with red bricks when we meet customer ?
If we take the size 4*8*24
market price now in India is 3500Rs per each cubic meter
Red bricks market price now in India is 2357Rs per each cubic meter its varies city to
city .
So the first question comes from customer why i spend more money for clc bricks?

Here is the solution

Take an example:
1 unit wall brick construction with clc and red brick
Clc bricks for 1 unit wall construction red bricks for 1 unit wall construction
Clc bricks for 1 unit wall construction Red bricks for 1 unit wall construction
1) clc bricks for 1 unit wall around 75 bricks 1) red bricks for 1unit wall comes comes
around 560 bricks
2) quantity of cement and sand requires for motor 1unit wall
cement : 1 bag cement
sand : 4bag sand
price : 300Rs for cement
100 Rs for sand
---------------------------------Total 400 Rs/----------------------------------- 2) quantity of cement and sand requires for motor 1unit wall
cement : 2.5 bag cement
sand : 10 bag sand
price : 625 Rs cement
250 Rs for sand
---------------------------------Total 875 Rs /----------------------------------3) Plastering:
inch plastering is Enough
Cement : 1.5 bag cement
Sand : 6 bag sand
Price : 450 Rs for cement
150 Rs for sand
---------------------------------Total 600 Rs/----------------------------------- 3) Plastering:
1.5 inches plastering is needed
Cement : 3.5 bag cement
Sand : 14 bag sand
Price : 940 Rs for cement
350 Rs for sand
---------------------------------Total 1300 Rs/----------------------------------Total cost for plastering and motor joints For clc bricks
600 + 400 = 1000Rs
Total cost for plastering and motor joints

For red bricks

1300 + 875 = 2175Rs
Red bricks for 1 unit wall price is
4 * 560 = 2240RsClc bricks for 1 unit wall price is
45*75 =3375Rs If we subtract clc price from red brick price
3375
2240
-----1135
Now add plastering and motor joints price
Ie 2175
1135
--------3310
--------So at the end of the 1 unit wall construction the price we are spending for red bricks as
almost same as clc bricks apart from that contractor can construct the building less time
then red brick construction. So finally customer can happy
To get good product in the market to build is home
Note : The above calculation we are giving for construction a building with clc its varies
cities and cities .
-- Srinu Vuggina, November 24, 2011
Contribute a response
Responses
why use clc light weight bricks in construction?
Srinu, is "clc" a brand name or an abbreviation for the material used?
-- Frank John Snelling, November 30, 2011

What is CLC
Cellular Lightweight Concrete (CLC), is a version of lightweight concrete that is
produced like normal concrete under ambient conditions. It is produced by initially

making a slurry of Cement + Fly ash (Optional) + Sand + Water, which is further mixed
with the addition of pre-formed stable foam in an unique Foamed concrete mixer. The
mixture is either poured or pumped into assembled moulds of bricks or form-work of
reinforced structural elements or poured onto flat roofs or voids for thermal insulation or
filling. The foam imparts free flowing characteristics to this slurry due to ball bearing
effect of foam bubbles enabling it to easily flow into all corners and compact by itself in
the moulds/forms without requiring any kind of vibration or compaction.
Cellular Light Weight Concrete (CLC) technology has been used in over 45 countries of
the world over the past 30 years to construct Over a hundred thousand houses,
apartments, schools, hospitals, industrial, commercial buildings etc.
The introduction in India of a modified version using over 40% fly ash has made it an
even more eco-friendly and cost effective version of CLC. The new product is set to
revolutionize the manner in which buildings are constructed. In the process, the product
brings quality housing closer to the masses at a faster and at a lower cost.

CLC Bricks
Cellular Lightweight Concrete (CLC) bricks are environment friendly and manufactured
from common natural raw material. The energy consumed in the production process is
only a fraction compared to the production of other materials and emits no pollutants and
creates no toxic products or by products. The CLC bricks that we offer provides thermal
and sound insulations and also fire protection eliminating need for many layers of
plastering and do not emit any toxic gas when exposed to fire. These bricks are highly
strong and of customized shape thus requiring less amount of cement and plastering and
giving an even shape to the construction.

Brickwells manufacturing unit located at

multiple cities, supplies CLC Bricks to residential, commercial and industrial real-estate
developent projects across India.

Brickwells wholly owned manufacturing unit can produce CLC Bricks as per standard
industrial sizes or tailored for your specific requirements. CLC Bricks are available in 3
grade strengths:

Grade A: These are used as load bearing units & have a brick density in the range
of 1,200 kg/Cum 1,800 kg/Cum
Grade B: These are used as non-Load bearing units & have a brick density in the
range of 700 1,000 kg/Cum.
Grade C: These are used for providing thermal insulation & have a brick density
in the range of 400 600 kg/Cum.

Technical Specifications of CLC Bricks:

Technical Specifications of CLC Bricks

Brick Size
(mm)
600 x 200 x
200
600 x 200 x
150
600 x 200 x
100

Approximate Weight/Brick
(Kg)

No. of
Brick/Truck

No. of
Bricks/Cu.Mtr.

20.500

305

41

15.500

416

55

10.250

610

83

Grade wise comparison of CLC Bricks:

Grade-wise Technical Comparison of CLC Bricks

Type Density Min. Compressive Strength N/mm2 Water Absorption %
Grade A 1800 25.0
7.5
1600 17.5
7.5
1400 12.0
10.0
1200 6.5
10.5
Grade B 1000 3.5
12.5
800
2.5
12.5
Grade C 600
1.0
15.0
400
0.5
15.0

What is CLC?
Advantages of CLC
Comparison of CLC with traditional building materials
Insulation / Flooring / Roofing using CLC
Discover foaming agents by Isoltech Italy

Cutting Machine developed by Brickwell

Advantages of CLC
Advantages of CLC Bricks

CLC Bricks have excellent compressive strength in excess of regular clay bricks /
solid blocks, guarantees min. Compressive strength of 3N/mm2.
Bending strength is 15 to 20% of compressive strength.
CLC Bricks density is 800kg/m2 which reduces dead load on structures.
Huge saving in foundation and structure savings upto 30% on beam costs.
Good earth quake resistance properties.
Easy handling.
Faster construction.
Huge saving of labour.
CLC Bricks offer highest thermal insulation making cool summers and warm
winters.
Reduced Air conditioning expenses.
CLC Bricks are fire resistant.
Non toxic fumes in case of fire.
Excellent acoustic barrier. More peace of living, No disturbance from your
neighbours home theatre.
Highly accurate and smooth walls reduction in plastering.
Opt for any finish on walls external plastering, tiling, cladding, internal tiling,
dry lining, spray plaster or anything of your choice.

Comparison of CLC
S. Parameters
No.

Cellular Lightweight
Concrete Bricks

Autoclaved Aerated Concrete/Ho Burnt Clay

Concrete Blocks
llow
Bricks

1.
2.

3.

4.
5.

Concrete
Blocks
Basic raw
Cement, Sand, Aggregate,
Cement,
Cement, Sand, Fly Ash
Top Soil &
materials & Fly Ash, Water & Foaming
Sand &
& Acration Compound
Energy
other inputs
Compound
Aggregate
General
Properties
Dry Density
800- 1200400
650
750
1200-2400
1900
3
kg/m
1000
1800
125Compressiv
40-60
20-30
180
e Strength
(Grade
35
40
30-60
40-125
(Grade
A)
(Grade
3
in kg/cm
B)
C)
Reinfor
Range of
Non-load
Non-load Load-bearing
ced
Reinforced
applications Insulation Partition
bearing
Bearing
& non-load
element
panels
/ utility
blocks
Walls
bearing
s
No gain in
No gain in
No gain in strength
Aging
Gains strength with age
strength with strength with
with age
age
age
3
0.132-0.151 for 800 kg/m
Thermal
0.132-0.151 for 650
Conductivit
0.184
kg/m3
y (W/m.k.)
0.238 for 1000 kg/m3
Sound
Superior than burnt clay &
Superior than burnt
Good
Normal
Insulation
hollow concrete
clay & hollow concrete
Ease of
Can be cut, nailed & Difficult to
Can be cut, nailed & drilled
Normal
Working
drilled
work
Shape &
Form
Pre-cast
600 x 200 x 100/200 400 x 400 x 230 x 100 x 70
600 x 200 x 100/200 mm
Brick size
mm
100/200 mm
mm
Pre-cast
Any size of elements
Any size of elements Not feasible Not feasible
elements
Cast in
Any shape & size in any
Not feasible
Not feasible Not feasible
shape
density
12% for 800 kg/m3 density
Water
(by volume)
Absorption
20% by
20% by
45% by volume
% by
volume
volume
3
weight
7.5% for 1800 kg/m density
Drying
0.05 Grade A
Shrinkage after
0.07 (M-25 No shrinkage
Shrinkage
maturing
Concrete)

0.011 (for 1200 kg/m3)

mm/meter

6.

Productivity

0.10 Grade B
Output 100% more than
brick work
Pollution free

7.

Eco
Friendliness

Least energy requriement

0.058 (for kg/m3)

Output 100% more
than brick work

50% higher
than brick

Creates
smoke

Pollution free
High energy
requirement

Can consume fly ash around

Open process uses fly
33%
ash

Medium
energy
No smoke

55% reduction in
weight of walls.

8.

Normal

Uses high
energy
Wastes
agricultural
land

55% reduction in weight of

Structural
walls.
saving due
Marginal
Tremendous structural
to dead
dead weight No additional
Tremendous structural
saving for high rise
weight
reduction
saving for high rise buildings
buildings in
reduction
in Earthquake / Poor soil area Earthquake / Poor soil
area

CLC Flooring

Brickwell CLC is used for roofing and

flooring applications extensively.

A low density mix is chosen and the resulting air content gives the material excellent
thermal insulation properties. The low density also has the advantage that it does not
significantly add to the overall weight of the roof.
Foamed concrete has two benefits when it is used for roofing. The first benefit is that it
provides a high degree of thermal insulation. The second benefit is that it can be used to
lay a flat roof to falls, i.e. to provide a slope for drainage. Foamed concrete is also much
lighter than slopes made from mortar screeds. This means that a roof with a slope made
of foamed concrete imposes a lower loading on the structure of the building.
CLC can be produced and poured for floors and roofs on-site. In roofs it can be used
because of very good insulation properties and it is comparatively lightweight.
For floors CLC offers faster installation and a less expensive option because of the
flowing and self-leveling properties.

Foaming Agents
For the production of cellular concrete, Brickwell has tied up with Isoltech, a world
leader in CLC Manufacturing Solutions. Brickwell offers to its clients the quality and
effectiveness of the foaming agents ISOCEM S/L and ISOCEM S/B-P.
ISOCEM S/L

Isocem S/L is a foaming agent for cellular

concrete, developed by Isoltech.
The properties of cellular concrete obtained by using the specific foaming agent Isocem
S/L, however, are influenced by the foam/cement ratio, rather than by the properties of
the foam itself, and this ratio determines the final heat and sound insulation properties ot
cellular concrete.
ISOCEM S/L is an innovative foaming agent, made up of natural surfactants mixed to
vegetable raw materials: it is highly effective and can also be used as an air-entraining
additive for cement mixes containing light aggregates (EPS, vermiculite etc.).

Physical Properties:
The most significant physical property of cellular concrete is its density. It is determined
by the quantity of air in a cubic meter of material, that is by the air/cement ratio. The
most frequently used densities are:300 kg/m3400 kg/m3500 kg/m3600 kg/m3
These densities correspond to different values of thermal insulation and mechanical
resistance, which approximately amount to the values in the following tables:

D 300 kg/m3 = 0.062 kal/m/h/C

D 400 kg/m3 = 0.08 kal/m/h/C
D 500 kg/m3 = 0.09 kal/m/h/C
D 600 kg/m3 = 0.12 kal/m/h/C

Doses: 2.5-3% (percentage of foaming agent for the production of cellular

concrete).Applications: layers and/or sloping terraces.
Storage: 1000 kg tanks or 200 kg drums.
Description and Features:
Isocem S/L is a foaming agent for cellular concrete, developed by Isoltech. Its main
features are the following:

Isocem S/L Description

Physical properties Isocem S/L
Appearance
liquid
Colour
light brown
Density
1025 g/l
PH
7
Freezing point
-2 C
ISOCEM S/B-P
ISOCEM S/B-P is a foaming agent made up of protein hydrolysates, which form a highly
stable foam; it is used to produce building blocks with specific foam generators and can
be used in all medium density mixes of cellular concrete and sand, from 600 to 1200
kg/m3.
Properties:

Absorption: Trials have shown that the foaming agent ISOCEM S/B produces a
cellular concrete with very low water absorption. The higher the air content, the
higher the water absorption: a fully submerged, medium density (770 kg/ m3)

sample of cellular concrete absorbs only 13% of the weight of water over a 10
days period.
Fire resistance: Cellular concrete is extremely fire resistant and well suited to
applications where fire is a risk. Tests have shown that in addition to prolonged
fire protection, the application of intense heat, such as a high energy flame held
close to the surface, does not cause the concrete to spall or explode as is the case
with normal weight concrete.
Reliability: Foam concrete is not subject to the impact of time: it does not
decompose and is as durable as rock. Its high compression resistance allows to
use it with volumetric weights that reduce the global weight of a building.
Heat: Due to a high temperature lag, buildings made of foam concrete are able to
accumulate heat, which allows to minimize heating expenses by 20-30%.
Microclimate: Cellular concrete prevents loss of heat in winter, is moisture
resistant, allows to avoid very high temperatures in summer and control air
humidity in a room by absorbing the output of moisture, thus helping to create a
favourable microclimate (like in a wooden house).
Quick mounting: The small density (and therefore the lightness) of foam concrete
and the large size of blocks compared with bricks allow to increase the speed of
laying by several times. Foam concrete is easy to process and trim, to cut channels
and holes for electrical wiring, sockets, and pipes. The simplicity of laying is
reached through high exactness of linear dimensions: the tolerance is +/- 1 mm.
Sound insulation: Cellular concrete has a relatively high property of acoustic
absorption. Buildings made of porous concrete meet the requirements for sound
insulation.
Environmental compatibility: During maintenance, foam concrete does not
produce toxic substances and in its ecological compatibility is second only to
wood. As a comparison, the coefficient of ecological compatibility of porous
concrete is 2; of wood 1; of brick 10; of expanded clay 20.
Versatility: Due to its high workability, it is possible to produce various shapes of
corners, arches, pyramids, which can enhance the architectural and aesthetic value
of buildings.
Cost-effectiveness: The high geometrical exactness of dimensions of concrete
production allows to lay blocks on glue, to avoid frost bridges in a wall and to
make inner and outer plaster thinner. Cellular concrete weighs from 10% to 87%
less than standard concrete. A sufficient reduction of weight leads to a sufficient
economy on basements.
Safety: Foam concrete is protected from fire spread and corresponds to the first
degree of refractoriness. Thus, it can be used in fire-proof constructions. Under
the impact of intensive heat, like that of a blow lamp, the surface of foam concrete
does not split or blow, as is the case with standard concrete. As a result, the
armature is protected from heating for a longer period.
Transport: The compact size of systems and their low cost allow to distribute
them near the target markets, thus saving on transport costs.

Isocem S/B Comparison

Density (kg/mc) Cement kg Sand kg Water l. Isocem S/B kg

600
310
210
110
0.9
800
350
370
120
0.8
1000
370
560
125
0.7
1200
400
750
140
0.65

Isocem S/B Properties

Thermal density (kg/m3) Mechanical resistance Insulation
600
1.2
0.12
800
2.0
0.21
1000
3.0
0.24
1200
4.5
0.38

IN THE PRESENT SCENARIO WHERE CONSTRUCTION IS AT PACE THESE

CELLULAR LIGHT WEIGHT CONCRETE [C.L.C] BLOCKS SAVES TIME AND
MONEY.THE THERMAL INSULATION PROPERTY OF THE CELLULAR LIGHT
WEIGHT CONCRETE BLOCKS SAVES ELECTRICITY COSTS.WHO ARE
INTERESTED TO SET UP NEW C.L.C INDUSTRY PLEASE MAIL US AT
spektraoffice@gmail.com OR CALL US AT 09581563999,916036399,9885263999
==============================================