FAQ about AirCrete

What is AirCrete? AirCrete is a lightweight cementitious material that contains stable

air cells uniformly distributed throughout the mixture. It is a concrete which utilizes a stable air
cell rather than traditional aggregate. It is also called cellular concrete, foam concrete, light
weight concrete, aerated concrete etc.
What is the correct water to cement ratio for the cement
water slurry?
Typically, a (1 to 2) water to cement ratio slurry is used as a base mixture for AirCrete. The
water cement ratio may be varied according to specific project requirements. We use 6.5 gallons
to 94 lbs of cement.
Does AirCrete contain either fine or course aggregate?
AirCrete may contain sand but not coarse aggregates. Air-crete is designed to create a product
with a low density and a relatively lower compressive strength when compared to plain concrete.
The typical density range of Air-crete is 20 – 60 lbs/cu.ft. which develops a corresponding
compressive strength range of 50 psi – 930 psi. When higher compressive strengths are required,
the addition of fine and less foam will result in a stronger concrete with resultant higher
densities.
What type of cement is appropriate for AirCrete? AirCrete may be
produce with any type of portland cement or portland cement & fly ash mixture. The
performance characteristics of type II, type III and specialty cements carry forward into the
performance of the AirCrete.

How much AirCrete does a bag of cement produce? A 90lb bag of

cement produces 40 - 50 gals (3.5 cubic feet or @ 0.1296296296296296 cubic yards) weighing
between 20 and 60 pounds per cubic foot of AirCrete. The cost of Portland cement varies from
under $.04-$.11 per pound; that would translate to $4 to $11 for a cubic yard. Concrete is normally
measured in cubic yards. To determine how much you'll need, figure the volume inside your forms in
cubic feet and divide by 27 (the number of cubic feet in a cubic yard). For example, a 4-in.-thick slab
that covers 90 sq. ft. takes up 30 cu. ft., or just over 1 cubic yard.

Cost for 1,000 sq ft house with BioAirCrete wrap;

What are the advantages of AirCrete? There are many benefits to

AirCrete in the appropriate application. It is inexpensive to produce, it has good compressive
strength, it bonds well, easy to work with, self compacting, self leveling, uses less material, and
offers enhanced sound and heat insulating properties. AirCrete is very easy to clean up and can
be remove with only hand tools.
Are there different methods for manufacturing AirCrete?
AirCrete is commonly manufactured by two different methods. Method 1 consists of mixing a
pre-formed foam into the cement and water slurry. Method 2 consists of the addition of reactive
substances, which produce gas bubbles when in contact with the cement and water slurry.
What are the advantages of pre-formed foam?
The pre-formed foam process assures a consistent distribution of air cells.
What are the disadvantages of AirCrete compared to typical
concrete?
In the lower density ranges AirCrete becomes more brittle and has less compressive strength than
plain concrete. While this may be a disadvantage in plain concrete applications, it is an
advantage in an AirCrete application. It should be considered that AirCrete and plain concrete
are used for different types of applications. Each form of concrete exhibits a unique family of
performance characteristics. Each should be utilized in the appropriate type of project.
What construction projects are appropriate for AirCrete?
• Housing Systems
• Precast Blocks and Panels
• Floor Slabs
• Poured Insulated Roof and Floor Decks
• Underground Pipe Insulation
• Acoustic Floor Underlayments and Shock Absorption
• Load Reducing Fill over Underground Structures
• Fill for Abandoned tanks, mines and pipelines
• Replacement for Unstable Soils
• Bridge Approach Fills
• Land Fills
Do the bubbles in AirCrete collapse, reducing its volume?
Yes it does collapse in the case of vertical pours where the force of gravity exceeds the air cell
strength. Air cell stability is the mark of a good foam concentrate and foam generator
combination. Which is not to say that all AirCrete products are stable. If you unfamiliar with the
foaming agent you should test the foam for stability prior to use. With dish detergent as foaming
agent expect some collapse if the depth of pour exceeds 3'.
What Ad Agents are common to AirCrete?
Fiber reinforcement - Heat-of-hydration reducers (iced water or chemicals) - Compressive
strength enhancers - Coloring pigments or color enhancing agents
How far can AirCrete be pumped?
Documentation of AirCrete being pumped 500 ft. vertically and 10,000 horizontally is common.
How do you finish AirCrete?
In most cases AirCrete is covered by another material. It make a good sub floor but can't be
polished like regular concrete. The exterior walls are best covered with a thin layer of water
proof crack resistant stucco. Interior walls can be finished with a thin layer of plaster and paint. It
is an excellent base for natural plaster.
How much does AirCrete cost?
This depends of several factors. The density, the cost of cement, the additives etc. To calculate
the approximate cost of AirCrete for a dome structure, including subfloor slab - multiply the
square feet X the inches of thickness. For example a 1000 square foot dome 4 inches thick will
cost about $4000.
Is AirCrete suitable for long-term use as a marine float
device?
AirCrete will float, and in many cases float indefinitely. For best results AirCrete used for
marine flotation should be encased in a protective membrane or shell.
Is it appropriate to reinforce AirCrete with fibers?
Yes, fiber will increase the tensile strength. Fiber reinforcement is a mechanical process and does
not have any effect on the chemistry of concrete. It is therefore perfectly acceptable to design
fiber reinforced AirCrete just as it is done with other forms of concrete.
Is it appropriate to reinforce AirCrete with steel?
Yes, steel reinforcement is appropriate in situations where more tensile strength is required.
There is no chemical or mechanical reason not to reinforce AirCrete with steel.

• Lightweight aggregate block

Produced in greater volume, but less strong than dense blocks, lightweight blocks are used in both
internal and external walls where loading is slightly more restricted or as infill blocks in beam and
block flooring. Their main advantage over dense aggregate blocks comes from a combination of
higher insulating properties and a lighter unit weight. The lighter block enables time and material
cost savings through easier handling and larger units. Units the same size as other block types.

Lightweight blocks are manufactured from cement together with one of a variety of natural or man-
made expanded aggregates including: granulated / foamed blast-furnace slag, expanded clay or
shale, furnace bottom ash (FBA), pulverized fuel ash (PFA), or the less common pumice (a volcanic
material). The density of the aggregate is generally proportional to the strength of the block - so for
example ‘super-lightweight’ aggregates such as expanded clay and pumice used for their excellent
thermal performance, feature a relatively low compressive strength.

• Typical thermal conductivity: 0.25 - 0.60 W/mK

• The typical density range of Air-crete is 20 – 60 lbs/cu.ft. which develops a

corresponding compressive strength range of 50 psi – 930 psi. When higher compressive
strengths are required, the addition of fine aggregates and less foam will result in a
stronger concrete with resultant higher

• USE BIOCHAR IN THE POURED PRODUCT

o grind the biochar to a granular state that is approximately equivalent to sand
o premix it with water in a blender that breaks the particles on and distributes them
when the water. This way they will be less likely to affect the density of the final
product
 o allow to soak for at least a couple days so that the water can be absorbed into the
biochar
o http://www.ithaka-journal.net/pflanzenkohle-zum-hauser-bauen-stadte-als-
kohlenstoffsenken?lang=en
• DON’T USE FIBERS IN POURED PRODUCT – CAUSE INCREASE IN THERMAL CONDUCTIVITY
• USE FIBERS IN COATING PRODUCTS USED FOR FINISHING; THIS IS ALSO WHERE WE COULD USE
THE PIGMENTS
• How much AirCrete does a bag of cement produce? A 90lb bag of cement produces 40 - 50 gals
of AirCrete.
o
• Grass clippings or hay or oak leaves after falling in fall or chopped up clothing or chopped up
plastic bags or chopped up plastic ropes or chopped up plastic bottles or etc. etc. etc. used as
fiber/filler