We prepare polystyrene concrete blocks with our own hands. Technology for self-production of polystyrene concrete How to make polystyrene foam blocks yourself

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Home / Articles / Methods for preparing polystyrene concrete (expanded polystyrene concrete) based on SDO.

SDO is used in the form of an air-entraining additive to obtain a porous effect, which is necessary for the optimal selection of the composition of the PSB mixture, firstly, to prevent the effect of delamination of the mixture, secondly, for the most uniform distribution of PS granules in the total volume of the mixture, and thirdly, how antifreeze additive.

The role of SDO in a polystyrene concrete mixture is multifaceted, but the most important thing that can be achieved with the help of SDO is a slight porosity of the cement paste in the mixture. This is necessary in order to increase the resistance to the upward movement of the polystyrene granule (it tries to float up and separate the mixture). SDO produces bubbles from entrained air that are significantly smaller (up to 1 µm) in diameter than other additives (5 µm and above). As a result, products using SDO are stronger and more durable; by creating very small spherical air bubbles (with a diameter of up to 0.3 mm), the volume of the cement mortar increases and the difference in density between the cement mortar and lightweight polystyrene foam filling decreases. The mixture acquires a plastic viscous consistency. Thanks to this, the floating of the polystyrene foam filler is prevented even in the case of intense vibration compaction and the workability of fresh polystyrene concrete is significantly improved. It is impossible to obtain a non-separating PSB mixture without using SDO (polystyrene floats).

Material consumption rate for the production of 1 m3 of polystyrene concrete mixture.

(example for different brands).

Brand by density,	Portland cement M 400 (M 500)	Polystyrene	SDO (conc. 50%)
Brand by density,	Portland cement M 400 (M 500)	PSB-S, PVG	SDO (conc. 50%)

Note: If it is necessary to obtain polystyrene concrete D500 with a strength of 2.0-2.5 MPa, expanded polystyrene with pH = 25-30 kg/m³ of a fraction of 0-5 mm should be used.

Preparation of polystyrene concrete mixture.

The polystyrene concrete mixture is prepared in a forced-action concrete mixer.

From the beginning, polystyrene foam gravel dosed by volume is fed into the mixer, then it is mixed for 30 seconds. with 1/3 of the SDO working solution to wet the gravel with resin for better adhesion. After this, dosed cement is loaded into the mixer and the mixture is mixed for another 10-20 seconds. Next, the remaining portion of water and the working solution of the SDO additive are poured. The mixture is stirred for at least 1 minute. until a cohesive porous homogeneous structure is obtained.

The total mixing time of all components of the mixture must be at least 3 minutes. During the mixing process, visual monitoring of the consistency and workability of the polystyrene concrete mixture should be carried out.

Density according to GOST 10181.2 in a two-liter measuring container. It must be within the limits specified in the table

Methods for preparing foam concentrate for polystyrene concrete.

Dilute liquid (~50%) saponified wood resin (SDO) with water (t=25-400C) in a volume ratio of ~1:4 and mix. A ~10% working solution with a density of at least 1017 kg/m3 was obtained. Prepare a 10% solution of lime milk (from powdered quicklime) with a density of 1055-1057 kg/m3. Milk of lime is a foam stabilizer. Add a solution of lime milk in a volume ratio of 1:1 to the working solution of SDO resin, stir the mixture until it becomes uniform.

Powdered saponified wood resin (SDO) is diluted with water (t = 50-700C) in a ratio of 1:9 by weight (~ 900 g of water per 100 g of powder) and mixed. A ~10% working solution with a density of at least 1017 kg/m3 was obtained.

Prepare a 10% solution of lime milk (from powdered quicklime) with a density of 1055-1057 kg/m3. Lime milk is a foam stabilizer. Add a solution of lime milk in a volume ratio of 1:1 to the working solution of SDO resin, stir the mixture until a uniform mass is obtained.

glavchem.com

Polystyrene concrete - polystyrene concrete manufacturing technology | Composition, recipe

Ready-made sets of equipment for the production of polystyrene concreteUp to 80 m3 per shift | Up to 50 m3 per shift | Up to 30 m3 per shift

Polystyrene concrete manufacturing technology

Lightweight concrete with expanded polystyrene aggregate - known as polystyrene concrete, is a lightweight concrete with a mineral binder, the pores of which are formed by particles of expanded polystyrene foam used as aggregate. The exceptionally low bulk density of foamed plastic particles allows the production of lightweight concrete with a bulk density range that can be selected to suit the requirements of a particular application, and the concrete has a correspondingly wide range of characteristics.

Lightweight concrete with expanded polystyrene filler (polystyrene concrete), thermal insulating plasters based on expanded polystyrene concrete have been known for a long time. While polystyrene concrete has been known for at least 25 years in our market, and in the Western market for more than 40 years, to date, expectations regarding the volume of use of polystyrene concrete have only been met in some areas of application. However, there has been a growing interest in polystyrene concrete in the building materials industry, indicating some changes in this regard, mainly due to the following reasons:

polystyrene concrete has become a serious alternative to foam concrete and aerated concrete, due to its wider range of applications, ease of manufacture and significantly better material characteristics
requirements for thermal insulation of buildings are becoming much more stringent, as a result of which it has become necessary to functionally separate building materials into thermal insulation and load-bearing ones, and these materials must be properly combined in building elements. In this regard, interesting solutions are offered by the use of lightweight concrete with expanded polystyrene (polystyrene concrete) filler.

This article reviews the current state of polystyrene concrete technology, with due emphasis on the use of recycled polystyrene as well as recently developed polystyrene concrete systems.

Description of polystyrene concrete

Lightweight concrete with polystyrene foam filler is part of a group of extremely lightweight concretes that are produced using porous aggregates that usually have low grain strength. The decisive factor for strength properties is the structure of the hardened cement paste surrounding the foam aggregate particles and influencing the mass of the concrete. In addition, the shape and size of the grains, as well as the surface structure of the polystyrene foam aggregates used, are important. Unlike mineral fillers, the dosage of polystyrene foam fillers is specified not by weight, but by volume. Thus, it is possible to precisely set the pore volume and, thanks to this, the volumetric mass of polystyrene concrete, and produce polystyrene concrete with a closed-cell structure. By selecting the bulk density of concrete, the characteristics of polystyrene concrete can be influenced to better suit specific requirements. In light of today's requirements, polystyrene concrete is of interest, the bulk density of which is in the lower range (< 600 кг/м3). В этом случае сочетание <теплоизолирующего материала>And<бетона>in one material offers builders an optimal combination of load-bearing properties, sound insulation, thermal insulation and fire protection. Already a few years after the invention of expanded polystyrene concrete, called Styropor (1951), BASF carried out the first preliminary tests on the use of expanded polystyrene as aggregate for the production of polystyrene concrete (styropor concrete). Since the high cost of this raw material initially prevented its profitable use as a lightweight aggregate, new research began at the end of 1967, and its intensity began to gradually increase. By this time, lightweight polystyrene foam aggregates had become an interesting alternative to lightweight mineral aggregates, and even despite their price, there was growing interest in new polystyrene concrete building products. To create the necessary preconditions for their entry into the market, BASF has taken the following measures:

development of formulations for various polystyrene concrete mixtures, allowing them to be reproduced in practice
confirmation of all important characteristics of the building material by tests carried out by official organizations
development and dissemination of cooking and styling methods
carry out and evaluate practical tests to confirm the success of the application
assistance and technical advice to material manufacturers regarding the development of production systems.

All these measures have been completed in our country and there are all the prerequisites for the active use of polystyrene concrete. Unlike lightweight concrete with mineral fillers, foam concrete, aerated concrete, in the case of polystyrene concrete it is possible to produce lightweight concrete with a volumetric mass of less than 200 kg/m3 and, accordingly, good thermal insulation characteristics. Consequently, further development is concentrated on the production of polystyrene concrete falling in this lower volumetric mass range, and in particular on improving the properties of lightweight concrete with polystyrene foam aggregate, production technology and the development of building systems using polystyrene concrete. Expanded polystyrene with a bulk density of 10-25 kg/m3 is used as a polystyrene concrete filler, which does not affect the final strength of lightweight concrete. The grain size of foamed polystyrene particles is in the range of 0.5-3.5 mm, which makes it possible to obtain a finely porous concrete skeleton and raw materials with a particle size of 0.2 to 1.0 mm are used. Lightweight polystyrene foam filler has the following characteristic properties:

extremely low bulk density
good thermal insulation of foam particles, due to which there is virtually no water absorption
spherical shape, which is preferable from the point of view of static loads.

However, in the range of very low bulk densities, the hydrophobic properties of lightweight closed-cell polystyrene foam aggregates can have an adverse effect, since the low bond strength between the cement paste and the particle surface can lead to delamination of polystyrene concrete during preparation and placement. In the early years of practical use, this effect was counteracted by the introduction of additives that improve bond strength. A number of manufacturers are following this path, mainly trying to increase sales of additives, since Western manufacturers and some domestic ones use special brands of polystyrene foam with a large-porous particle surface or special devices that allow concrete to be laid without objections without such additives.

Waste polystyrene foam as lightweight filler

In Germany, about 40,000 tons of raw materials are currently used annually for the production of packaging materials for the production of expanded polystyrene, from which expanded polystyrene is produced in a volume of up to 2 million m3. These packaging materials contain 98% air, contain no CFCs, and can be recycled to serve any reasonable purpose again. Our country also has a sufficient amount of waste, and with the development of industry and the growth of product production, the issue of packaging recycling becomes acute. In this regard, systems have been developed for the recycling of polystyrene foam, allowing for complete recycling of used packaging materials received from industrial, commercial enterprises and private consumers. In this article we consider only the use of waste polystyrene in lightweight concrete. Fine grain<измельченный материал>, made from waste from the production of polystyrene foam packaging, is suitable for use in the production of building materials: as a pore-forming substance in the production of blocks, panels, and as a lightweight aggregate for the production of lightweight concrete (polystyrene concrete). To use crushed polystyrene foam as a lightweight aggregate, certain requirements must be met requirements in order to prevent a decrease in the quality of concrete. In terms of grain size and shape, the differences between<измельченным материалом>and freshly baked polystyrene foam particles should be as small as possible:

most of the grains should be round in shape
most of the grains should have sizes ranging from 0.5 mm to 4.0 mm
The crushed material should not contain very small particles.

These quality requirements can be satisfied if the following conditions are met:

using suitable crushers to separate the polystyrene foam particles in wheelbarrows in which they are fused together, so that the original spherical shape of the grains is retained to a very large extent
The particle size of polystyrene foam granules used for packaging materials is usually the size required for lightweight polystyrene foam core made from<свежего материала>, this is achievable by using appropriate screens in the crusher. Currently so prepared<измельченный материал>is offered by some Western manufacturers of packaging materials at prices ranging from 12 to 25 euros, which is much lower than the price level for freshly foamed lightweight polystyrene foam filler.

Also present on the Russian market<измельченный материал>, unfortunately rarely satisfying the above requirements. The compressive and flexural strength values obtained from the 28-day tests are, in each case, the average of three specimens. Compressive strength tests were carried out on cubes with an edge length of 20 cm, and bending strength tests were carried out on bars 70*15*15 cm. Compressive strength of polystyrene concrete samples made using polystyrene foam from<измельченного материала>- especially at the lower end of the range, the volumetric mass of polystyrene concrete is approximately 40% lower than that of polystyrene concrete made using fresh expanded polystyrene foam particles. The tensile strength in bending of both variants of polystyrene concrete within the specified range of volumetric masses is approximately at the same level. The use of polystyrene foam<измельченного материала>, compared to foamed polystyrene foam, does not affect thermal conductivity, since it primarily depends on the volumetric mass of polystyrene concrete. The use of polystyrene foam<измельченного материала>does not have a negative impact on quality requirements such as water absorption, frost resistance, fire resistance, etc.

Polystyrene concrete production technology

This section refers to special conclusions on the production technology of polystyrene concrete from 200 to 600 kg/m3 (dry volumetric mass), which has good thermal insulation properties and is light in weight.

Unlike lightweight concrete with expanded polystyrene aggregate, which has a density of more than 600 kg/m3, in this case it is necessary to consider some special features that have a significant impact on the homogeneity of the mixture, workability and flow of polystyrene concrete, as well as on the tendency to cracking and from shrinkage and delamination .

The decisive influence on the properties of fresh polystyrene concrete is that a very large part of its volume consists of expanded polystyrene particles. In the range of volumetric mass less than 600 kg/m3, the amount of cement mortar is insufficient to completely fill the volume<пазух>light filler. Without the addition of appropriate additives, polystyrene concrete in this bulk density range can only be placed and compacted with great difficulty due to its largely non-cohesive nature.

Adding large amounts of water will reduce the compressive strength and increase the tendency for shrinkage cracking and delamination.

To find out how the workability and compactability of polystyrene concrete can be improved, tests were carried out using various additives. As a result, it turned out that the greatest benefits are provided by additives containing air-entraining components, as well as components for stabilizing and liquefying the polystyrene concrete mixture. By creating very small spherical air bubbles (with a diameter of up to 0.3 mm), the volume of the cement mortar is increased and the difference in density between the cement mortar and lightweight polystyrene foam concrete filling is reduced. The mixture acquires a plastic viscous consistency. Thanks to this, the floating of the polystyrene foam filler is prevented even in the case of intense vibration compaction and the workability of fresh polystyrene concrete is significantly improved. A special position is occupied by protein foaming agents used in the mechanical production of air foams. They are characterized by a very stable foam structure. The mobility and excellent adhesion of these air foams has an extremely beneficial effect on the workability of polystyrene concrete, even in the case of relatively low water-cement ratios.

Elastic polystyrene foam aggregates and a relatively high proportion of air bubbles cannot counteract the shrinkage of hardened cement paste. However, the effect of excessive setting shrinkage and the tendency to crack can be reduced by keeping the polystyrene concrete wet for a sufficiently long time. In practice, adding cement-compatible reinforcing fibers to the mixture has proven to be very effective. The reinforcing fibers in the hardened cement paste skeleton of polystyrene concrete absorb the stresses generated by tensile shrinkage and temperature changes during the setting and hardening of polystyrene concrete, thereby reducing the tendency to crack and significantly increasing flexural tensile strength. Foam is added to the mixer during preparation of the mixture, for which a foam generator is used. Conventional mixers with forced mixing are suitable for preparing polystyrene concrete. Gravity concrete mixers are only conditionally suitable. To obtain a high-quality mixture, the components are laid in a certain sequence. The mixing time should be approximately 2 minutes. The volumetric dosage of expanded polystyrene gravel can vary within certain limits depending on whether fresh foam material is used or<измельченный материал>.

1.3. Compliance with the recommendations ensures the preparation of polystyrene concrete mixtures of optimal quality to obtain heat-insulating polystyrene concrete with a fairly wide range of applications and, accordingly, with a wide range of properties - dry density 200-500 kg/m3 with a compressive strength of 0.2-1.75 MPa.

2. Source materials.

2.1. Portland slag cement or Portland cement M400, which meets the requirements of GOST 10178, is used as a binder for the preparation of polystyrene concrete mixture.

If it is necessary to increase the strength of polystyrene concrete, above the values given in Table 1,

2.2. Granulated polystyrene foam with the following characteristics is used as a filler, depending on the requirements for polystyrene foam (Table 1)

Table 1

Characteristics of expanded polystyrene depending on the required

quality indicators of polystyrene concrete.

Note: if it is necessary to obtain polystyrene concrete D500 with a strength of 2.0-2.5 MPa

Expanded polystyrene with pH=25-30 kg/m3 of fraction 0-5mm should be used

2.3. Saponified wood resin SDO is used as an air-entraining additive,

meeting the requirements of TU 13-0281078-02-93, as well as other air-entraining additives that meet GOST 24211.

2.4. To increase the workability of the mixture, reduce operational humidity and the thermal conductivity coefficient of polystyrene concrete, plasticizing and water-repellent additives that meet GOST 24211 can be used.

In order to reduce the required consumption of portlace cement and the thermal conductivity coefficient of polystyrene concrete produced on it, part of the cement (up to 50%) can be replaced with finely ground (S = 2000-2500 g/cm2) additive of granulated blast furnace slag.

2.5. Water for preparing polystyrene concrete mixture must meet the requirements of GOST 23732.

3. Compositions of polystyrene concrete mixture.

3.1. The compositions of polystyrene concrete mixtures must be assigned by calculation and experimental method in accordance with the requirements of GOST 27006-85 on the basis of experimental batches, taking into account the characteristics of available materials and the parameters of technological equipment for the preparation, laying, compaction of the mixture, as well as taking into account the conditions of concrete hardening.

3.2. The approximate costs of materials for the preparation of polystyrene concrete mixtures of various grades by density can be taken from Table 2.

table 2

Estimated costs of materials for preparing polystyrene concrete mixture

different brands according to density.

Notes: 1. Water consumption is given based on the conditions for preparing a polystyrene concrete mixture with workability grade U-1. When preparing a polystyrene concrete mixture with workability grade U-2, water consumption should be increased by 10-15%.

The consumption of materials in the preparation of polystyrene concrete mixture for polystyrene concrete of intermediate grades in density (D250, D350, D450) is determined by interpolation.

4. Preparation of polystyrene concrete mixture.

4.1. High-quality polystyrene concrete mixture is prepared in a forced mixer. Preference is given to mixers with a horizontal shaft (type UNCD -70). The volume of the mixer is determined by the required productivity of the production line.

4.2. Dosing of materials is carried out in the following way:

4.2.1. Dosing of binder (cement) is carried out by weight in special weighing dispensers or by weighing on commercial scales.

4.2.2. Granulated expanded polystyrene foam is dosed by volume in a special dispenser or using calibrated measuring containers. It is advisable to weigh the polystyrene foam dosed by volume in order to control its bulk density.

4.2.3. Water dosage is carried out by volume using a flow dispenser or by volume using a calibrated container.

4.2.4. A 10% solution of the SDO additive (pl. - 1.017 g/m3) is dosed by volume using a calibrated measuring container. It is allowed to dose the SDO solution by weight through a weight or weight water dispenser.

4.3. The SDO additive, supplied to the polystyrene concrete mixture manufacturer's plant in solid form in paper bags, is mechanically broken into small pieces no larger than 20 mm in size and dissolved to a working concentration in hot water at t-80-90C with constant stirring or bubbling.

It is recommended to take the working concentration of the SDO additive in accordance with clause 4.2. It is allowed to use the SDO working solution without monitoring its density with densimeters. In this case, 1 kg of commercial SDO product is dissolved in 9 liters of hot water to obtain a solution of 10% concentration.

When SDO is supplied in barrels in liquid form (40-50% concentration), which is most desirable, the additive is diluted to a working concentration by dissolving with constant stirring (bubbling) in water at t-20-25C.

First, polystyrene foam dosed by volume is fed into the mixer, then it is mixed for 30 s with 1/3 of the mixing water. After this, dosed cement is loaded into the mixer and the mixture is mixed for another 10-20 seconds. Next, the remaining portion of water and the working solution of the SDO additive are poured. The mixture is stirred for at least 1 minute. until a cohesive porous homogeneous structure is obtained.

4.5. The total duration of mixing of all components of the mixture must be at least 3 minutes.

During the mixing process, visual monitoring of the consistency and workability of the polystyrene concrete mixture should be carried out.

4.6. After the preparation of the mixture is completed, at the beginning of each shift, as well as when new batches of binder, expanded polystyrene and SDO arrive, samples of the polystyrene concrete mixture are taken to check its density.

Density is checked according to GOST 10181.2 in a two-liter measuring container. It must be within the limits specified in Table 3.

Based on the density requirements for polystyrene concrete.

Note: The value of the densities of the polystyrene concrete mixture when preparing it for polystyrene concrete of intermediate grades in density (D250, D350, D450.) is determined by interpolation.

4.7. If the density of the selected sample of the polystyrene concrete mixture turns out to be higher than the values given in Table 3, carry out a secondary density check on the newly selected sample and, if the identified deviation is confirmed, the composition of the polystyrene concrete mixture is corrected by additionally introducing 10-15% SDO additive and (or) water in accordance with the recommendations of the control service.

4.8. After adjusting the composition, the mixture is stirred for an additional 2 minutes. m carry out secondary density control. Such operations are repeated, if necessary, 2-3 times until the required density characteristics are achieved.

4.9. If the density of the selected sample of polystyrene concrete mixture after a 3-fold check is lower than the requirements given in Table 3, the mixture composition is adjusted in the next batch by reducing the consumption of the SDO additive and (or) water by 5-10% until the required density characteristics of the mixture are obtained.

4.10. Then, during the shift, the mixture is prepared according to the adjusted dosage, periodically (1-2 times per shift) monitoring the density. If, in the process of adjusting the latter downwards, the required density of the mixture was obtained after repeating the batches 2 or 3 times, then in the following batches the additional costs of SDO and (or) water are reduced by 1.5 and 2 times, respectively.

4.11. The prepared polystyrene concrete mixture with the required density is discharged into the pump, and the pump delivers the mixture directly into the mold.

When using a polystyrene concrete mixture in a monolithic form, it is placed in the formwork of external walls or on complex coating slabs as thermal insulation, or in the voids of brick well masonry as insulation. The height of the fall of the polystyrene concrete mixture should not exceed 1.5 m.

4.12. The most effective way to transport and lay the prepared polystyrene concrete mixture is to use a gerotor pump, which allows you to move the mixture up to 60 m horizontally or 15-20 m vertically without delamination.

For this purpose, the UNCD-70 installation can be used, consisting of a mixer and a receiving hopper with a gerotor pump with a capacity of 700 liters.

stirolbeton.ru

polystyrene concrete composition and proportions per 1m3

DIY expanded polystyrene concrete

In the Construction and Repair section, to the question Components and proportions of polystyrene concrete asked by the author Anastasia Zonova, the best answer is that asthma will begin if the maximum permissible concentration for styrene is exceeded by about 1000 times, but you will learn about this when the maximum permissible concentration exceeds the permissible concentration by 1500 times or from a doctor

Answer from 2 replies[guru]

Hello! Here is a selection of topics with answers to your question: Components and proportions of polystyrene concrete

Answer from the husky [guru] with a regular concrete mixer, as I understand it, you call it a gravity mixer (pear or bell). You will not mix polystyrene concrete in it, because it mixes the components gravitationally, i.e. under the influence of gravity. Expanded polystyrene is light... very light! And therefore it will always be higher in some enclosed volume than cement and aggregate. To prepare polystyrene concrete, there are special closed-type forced-action concrete mixers with a compressed air supply. Only in them can you mix polystyrene foam with cement and sand. And also supply the concrete mixture through a hose to the laying site (and also with compressed air). Try looking for such a faucet in your area. With a compressor, I think it will be easier. And the proportions are as follows. For a cube of polystyrene foam with a weight of 25....35 kg of cement you need from 80 to 100 kg plus water about 50 liters. We collect weights - 35+100+50=185kg/m3 of polystyrene concrete. Adjustments to materials (especially water) for the first batches will be necessary. Read about the loading order and mixing duration on the internet. Polystyrene concrete is an excellent material for walls, as well as for screeding on floors

Answer from Daria V. [newbie] I know a good site where it is written in great detail about polystyrene concrete. You can read it)

Answer from 2 replies[guru]

Hello! Here are more topics with the answers you need:

Answer the question:

22oa.ru

Compositions of polystyrene concrete - Domostroy

1. Compositions of polystyrene concrete with a density of 500-800 kg/m3 with fly ash.

The following components are used to prepare polystyrene concrete:

Cement grade 400, water requirement 25-27%.
TPP ash, density 2.1 g/cm3 and water requirement 60%.
Foamed polystyrene.

The composition of the concrete was selected based on the fact that the volume of voids in foamed polystyrene should be filled with cement-ash mortar. Polystyrene consumption is in the range of 0.9-1 m3/m3. The binder content in the solution is from 50 to 100% by volume.

The required consumption of materials is determined by the formula:

Vc+Vz+V=Vempty.

Where Vc is the volume filled with cement,

Vз - volume occupied by ash,

B - water consumption,

Vempty is the volume of voids at a given polystyrene consumption.

Water consumption was determined taking into account the normal density of the cement paste and the water requirement of the ash.

В= Ц*НГ+З*Wз,

Where C and Z are the consumption of cement and ash, kg;

NG - normal density of cement paste, %;

Wз – water demand of ash, %.

Compositions of polystyrene concrete based on fly ash and their physical and mechanical properties:

Material consumption per 1 m3		Density, kg/m3
	Polystyrene, m3

domostroi.tv

Production of polystyrene concrete: manufacturing technology, compositions, recipe

Concrete is strong and durable, but cold. And the ever-increasing price of energy resources pushes us to search for methods for its insulation. There are two main directions in this: creating a “pie” using additional installation of insulating materials and adding insulation to the concrete solution itself. In the second case, the most effective is the use of polystyrene foam, the process of which we will consider in more detail in this article.

General provisions

The technology + compositions + formulation of polystyrene concrete were discovered in the middle of the last century. But at that time, its industrial production turned out to be too expensive, and its strength indicators were low according to GOST standards of that time. But modern times show a great need for insulating houses, and the cost of polystyrene foam has decreased significantly, which in combination has led to an increase in the popularity of the material in question.

Advantages

Adding polystyrene foam to concrete mortar is not the only method of insulating it. But let's compare the technical characteristics of various building materials, including concrete with various additives, as well as brick and wood:

Judging by the given indicators, polystyrene foam concrete allows for the greatest thermal insulation, and at the same time is least susceptible to hydrophobicity. Although it loses in density.

Tip: when concreting the floor, you can use leftover polystyrene foam that has undergone the crushing procedure. Although they have less strength, which is unacceptable in relation to the construction of walls, they are absolutely not inferior in all other respects to packaged purchased polystyrene foam balls and will save the family budget even more.

Possibility of making it yourself. You can order a ready-made solution, or you can make it yourself. Below we will look at both options in more detail.

Flaw

The main disadvantage of polystyrene concrete is its strength. If cement stone has it more than sufficiently, then foam plastic is a very fragile material.

Advice: carefully monitor the proportions of insulation added to the cement mixture. If its quantity is exaggerated, then the finished product will not be reliable enough not only for the construction of walls, but also for pouring the floor.

Manufacturing

As you can already understand from the above, the manufacturing technology of polystyrene concrete consists of adding foam balls to the cement mortar. This process can be approached amateurishly and professionally.

Amateur approach

If you need to make and insulate a cement screed in a house, bathhouse or garage once in many years, then buying special equipment for the production of polystyrene concrete for this purpose is not rational. You can take a simpler and cheaper route.

The instructions are:

We buy ready-made foam balls or collect and shred the remains of packaging made from a similar material. In any case, the grains should fall within the range of 0.5 mm to 4 mm.

We fill the concrete mixer with sand and cement in a ratio of two to one, and then start the machine.

After a few minutes of work, we fill in the crushed foam. Its volume should correspond to the amount of dry mixture already loaded.
Then add water, the amount of which should be half as much as the entire contents of the concrete mixer.

Tip: if the sand was used wet, then the volume of added water should be reduced. Otherwise the solution will be too liquid.

After the solution reaches a homogeneous mass that resembles buckwheat porridge in appearance, you can begin concreting the desired structure.

Professional approach

Here you will already need special equipment for the production of polystyrene concrete, which is not cheap, but if you are going to make money on the production of this material, then it will pay for itself quickly enough. Moreover, at the output you can get not only solutions, but also ready-made blocks, which are much more in demand and can be stored in a warehouse for a long time.

For example, let's look at the technical characteristics of the ARTUS 001 machine:

The production technology of polystyrene concrete involves, in addition to classical ingredients, the use of special additives to increase the adhesion of cement stone to foam plastic, since initially it is not high enough. When pouring the floor, this is not necessary, since it does not experience the load-bearing load of the entire building, but the blocks must be as reliable as possible.

Foaming agents will also be needed. They equalize the density of the binder mixture and polystyrene, which prevents it from floating to the surface and helps to distribute more evenly.

Here is an example of the proportions used for products of different densities:

Thus, the main thing is to maintain the correct proportions and monitor the proper operation of the machine in order to fill the warehouse with the necessary building material.

Conclusion

The production of polystyrene concrete is a relatively simple process, but it requires appropriate equipment and careful adherence to proportions. Even for one-time pouring of the floor, you will need a concrete mixer, since manually you will not be able to achieve uniform distribution of the foam balls, which will negatively affect the strength of the structure.

Strength is generally the main problem of the material under consideration, because of which it is very important not to exceed the amount of insulating filler.

The video in this article will provide you with additional information for consideration that is directly related to the above materials.

The production of polystyrene concrete blocks can both help you save on building materials and become a good source of income.

masterabetona.ru

Do-it-yourself polystyrene concrete for building a house: proportions, characteristics, video

Polystyrene concrete is a universal building material with many positive qualities. It has a cellular structure, consists of concrete and filler - granulated polystyrene. The possibility of do-it-yourself production on the construction site is its important advantage. Blocks can be of different sizes and configurations. Strict adherence to technology and recommendations during independent production ensures the production of polystyrene concrete, which is not inferior in its parameters to the factory analogue.

Polystyrene concrete consists of several components. This is a filler, water and a binder mixture, which is cement or gypsum. To improve properties, it is possible to introduce special additives. The necessary equipment for production is a concrete mixer; you will also need a shovel. Wooden boards will be needed to put together the formwork.

Stages and technology of production

The manufacturing process involves loading the components into a concrete mixer in a certain sequence and thoroughly mixing them until a homogeneous solution is obtained.

1. Place PVG filler in a concrete mixer, add water in the required amount and add additional additives.

2. Start the mixing process for 2 minutes.

3. Pour in the required amount of cement.

4. Mix in a concrete mixer for 3 minutes until a homogeneous porous composition is obtained.

5. Tar is added as a water-repellent component in the process. In this case, the solution is constantly stirred.

6. Pre-make wooden formwork by lubricating its interior with machine oil.

7. The finished solution is poured into special molds. Hardening takes no more than a day. The duration of setting depends on many factors: ambient temperature, activity of astringent chemical additives.

8. After the mixture has hardened, the block is removed from the mold and left to dry completely on a flat surface in a cool room. After two to three weeks, self-made polystyrene concrete can be used in construction.

Advantages and disadvantages of polystyrene concrete

Among the main positive properties are:

High strength and reliability.
Excellent heat and moisture insulation.
Fire safety.
Ease of processing, versatility of use.
Low volumetric weight.
Environmental friendliness.
Durability, service life is more than 100 years.
Affordable price.

Along with many advantages, polystyrene concrete also has several disadvantages that need to be taken into account during construction:

It does not burn, but under the influence of high temperature the granules can melt, which leads to the destruction of the blocks.
When using polystyrene concrete to build houses, you should consider a ventilation system. There will always be high humidity in such rooms.
Violation of production technology will lead to changes in properties.
The use of low quality granules often causes destruction and the formation of voids.

When making building materials on your own, use the tips given and take into account some of the nuances. This will help improve the quality of the process and avoid errors.

1. The strength of polystyrene concrete depends on the size of the granules. You can purchase ready-made components that have the optimal size. A cheaper option is to assemble a homemade device for crushing polystyrene foam.

2. Strength and thermal insulation parameters depend on the percentage of ingredients. Compositions with a density of 350 and 1200 kg/m3 are considered optimal for individual construction. The first one is lighter and is used for thermal insulation, arranging screeds and partitions. The second is dense, used as a structural material. At the same time, its thermal insulation properties are lower.

3. Strength is determined by the amount of binder component. As the proportion of cement or gypsum increases, thermal conductivity decreases.

4. To reduce the cost of polystyrene blocks, you can replace part of the cement with sand. The method is suitable for obtaining a composition with a density of more than 1000 kg/m3. The proportion of sand should not exceed 15%.

5. For a homogeneous solution, polystyrene should be loaded into the concrete mixer gradually. If the components are placed into the mixture at the same time, the necessary mixing will not occur.

Despite the simplicity of the polystyrene concrete production technology, errors and difficulties may arise during the process. Even a factory-made product does not always meet the stated characteristics.

hardstones.com

1. General Provisions.

1.2. The recommendations were developed based on the communication of the results of research and development work of the Research Institute of Reinforced Concrete Concrete and other organizations, as well as practical experience in the production of polystyrene concrete mixtures for various purposes at enterprises in the construction industry.

1.3. Compliance with the recommendations ensures the preparation of polystyrene concrete mixtures of optimal quality to obtain heat-insulating polystyrene concrete with a fairly wide range of applications, respectively, with a wide range of properties - dry density 200-500 kg/m3 with a compressive strength of 0.2-1.75 MPa.

2. Source materials.

2.1. As a binder for preparing a polystyrene concrete mixture, slag Portland cement (preferably) or Portland cement grade M400 (M300) is used, which meets the requirements of GOST 10178. If it is necessary to increase the strength of polystyrene concrete, above the values given in Table 1, while maintaining the grade M500.

2.2. Granulated expanded polystyrene foam with the following characteristics is used as a filler, depending on the requirements for polystyrene concrete (Table 1).

Table 1
Characteristics of expanded polystyrene depending on the required quality indicators of polystyrene concrete

Requirements by density, kg/m3	Requirements by strength, MPa	Bulk density expanded polystyrene, kg/m3	fraction expanded polystyrene, mm
200	0,20-0,25	10-15	2,5-10
300	0,50-0,75	10-15	2,5-10
400	1,00-1,25	15-20	0-10
500	1,50-1,75	15-20	0-10

Note: If it is necessary to obtain polystyrene concrete D500 with a strength of 2.0-2.5 MPa, expanded polystyrene with pH = 25-30 kg/m3 of a fraction of 0-5 mm should be used.

2.3. Saponified wood resin SDO is used as an air-entraining additive, meeting the requirements of TU 2453-013-10644738-00.

In order to reduce the required consumption of Portland cement and the thermal conductivity coefficient of the polystyrene concrete produced on it, part of the cement (up to 50%) can be replaced with a finely ground (S = 2000-2500 cm2 /g) additive of blast furnace slag from the Nizhny Tagil Iron and Steel Works, the introduction of this additive, which is especially effective in low-grade polystyrene concrete density (D200, D300), will, in addition, help improve the granulometry (achieve its continuity) of the mixture “cement-granular slag-expanded polystyrene gravel, 2.5-10 mm” and, as a consequence, increase the cohesion of the structure and workability of the concrete mixture.

2.5. Water for preparing polystyrene concrete mixture must meet the requirements of GOST 23732.

3. Compositions of polystyrene concrete mixture.

3.1. The compositions of polystyrene concrete mixtures must be assigned by calculation and experiment in accordance with the requirements of GOST 27006-85 on the basis of experimental batches, taking into account the characteristics of available materials and the parameters of technological equipment for the preparation, laying, compaction of the mixture, as well as taking into account the conditions of concrete hardening.

3.2. The approximate costs of materials for the preparation of polystyrene concrete mixtures of various grades by density can be taken from Table 2.

table 2
Estimated costs of materials for preparing polystyrene concrete mixtures of various grades by density

Materials	units change	Consumption per 1 m3 PSB D200	Consumption per 1 m3 PSB D300	Consumption per 1 m3 PSB D400	Consumption per 1 m3 PSB D500
Portland cement	kg	160	240	330	410
Expanded polystyrene, m3	m 3	1,0-1,1	1,0-1,1	1,0-1,1	1,0-1,1
Additive SDO (50%), kg	kg	1,0	0,8	0,7	0,5
Water, l		90-100	110-120	130-150	150-170

3.3 Material consumption in the preparation of polystyrene concrete mixture for polystyrene concrete of intermediate grades in density (D250, D35150, D450) is determined by interpolation.

4. Preparation of polystyrene concrete mixture.

4.1. The polystyrene concrete mixture is prepared in a forced-action concrete mixer. Preference is given to mixers with a horizontal shaft (type SM-290). The volume of the mixer is determined by the required productivity of the production line.

4.2. Dosing of materials is carried out in the following way:

4.2.1. Dosing of binder (Portland cement, Portland slag cement) and finely ground mineral additive is carried out by weight in standard weighing dispensers such as DC-500D or by weighing on commercial scales.

4.2.2. Granulated expanded polystyrene foam is dosed by volume in a special dosing hopper or using calibrated measuring containers. It is advisable to weigh polystyrene foam dosed by volume in order to control its bulk density.

4.2.3. Water dosage is carried out by weight using a standard weight dispenser DZh-200D or by volume using a calibrated measuring container.

4.2.4. A 10% solution of the SDO additive (P10 = 1.017 g/m3) is dosed by volume using a calibrated measuring container. It is allowed to dose the SDO solution by weight through a weighing water dispenser DZh-200D. To increase the dosing accuracy, it is recommended to use the additive in the form of a 5% solution (P5 = 1.0085 g/m3).

4.3. When SDO is supplied in barrels in liquid form (40-50% concentration), which is most desirable, the additive is gradually diluted to a working concentration by dissolving with constant stirring (bubbling) in water at t = 20°±5°C.

First, polystyrene foam gravel dosed by volume is fed into the mixer, then it is mixed for 30 seconds. with 1/3 of the mixing water. After this, dosed cement is loaded into the mixer and the mixture is mixed for another 10-20 seconds. Next, the remaining portion of water and the working solution of the SDO additive are poured. The mixture is stirred for at least 1 minute. until a cohesive porous homogeneous structure is obtained.

4.5. The total mixing time of all components of the mixture must be at least 3 minutes. During the mixing process, visual monitoring of the consistency and workability of the polystyrene concrete mixture should be carried out.

4.6. After the preparation of the mixture is completed, at the beginning of each shift, as well as when new batches of binder, expanded polystyrene gravel and SDO arrive, samples of the polystyrene concrete mixture are taken to check its density.

Density according to GOST 10181.2 in a two-liter measuring container. It must be within the limits specified in Table 3.

Brand of polystyrene concrete by density	Density of PSB mixture, kg/m3 at grade U-1	Density of PSB mixture, kg/m3 at grade U-2
D200	250-290	260-300
D300	350-390	360-400
D400	470-510	480-520
D500	570-610	590-630

Note: The density values of the polystyrene concrete mixture when preparing it for polystyrene concrete of intermediate grades in density (D250, D350, D450) are determined by interpolation.

4.7. If the density of the selected polystyrene concrete mixture sample turns out to be higher than the values given in Table 3, carry out a secondary density check on the newly selected sample and, if the identified deviation is confirmed, the composition of the polystyrene mixture is corrected by additionally introducing 5-10% SDO additive and (or) water in accordance with the recommendations of the control service.

4.8. After adjusting the composition, the mixture is stirred for an additional 2 minutes. and carry out secondary density control. Such operations are repeated, if necessary, 2-3 times until the required density characteristics of the mixture are achieved.

4.9. If the density of the sampled polystyrene concrete mixture after a 2-fold check is lower than the requirements given in Table 3, the mixture composition is adjusted in the next batch by reducing the consumption of the SDO additive and (or) water by 5-10% until the required density characteristics of the mixture are obtained.

4.11. The prepared polystyrene concrete mixture with the required density is unloaded directly into a mold installed under the mixer, into the hopper of a self-propelled concrete paver or into a dispensing hopper equipped with a sector gate. From a self-propelled concrete paver or dispensing hopper, the mixture enters the molds.

When using a concrete mixture in a monolithic form, it is placed in the formwork of external walls or on complex coating slabs as thermal insulation, or in the voids of a brick well as insulation. The height of the fall of the polystyrene concrete mixture should not exceed 1.5 m.

4.12. The most effective way to transport and lay the prepared polystyrene concrete mixture is to use a gerotor pump, which allows you to move the mixture up to 30 m horizontally or 10 m vertically without delamination.

For this purpose, the KPTP-1600 installation can be used, consisting of a foam generator, a mixer with a horizontal shaft with a capacity of 200 l, a receiving hopper (150 l) with a screw for supplying the mixture to a gerotor pump and a gerotor pump for feeding and placing the mixture.

If there is a mixer, only the receiving hopper with an auger and the gerotor pump of this installation can be used for transporting and laying the mixture.

List of regulatory documents referenced in these TUGOST 7067-87 Construction materials and products. Method for determining thermal conductivity, clause 4.7
GOST 7473-94 Concrete mixtures. Specifications, clause 3.7
GOST 9758-86 Porous inorganic fillers for construction work. Test methods, clause 4.2
GOST 10178-85 Portland cement and Portland slag cement. Technical specifications, clause 2.1 (Appendix A)
GOST 10180-90 Concrete. Method for determining strength using control samples, clause 4.1 and clause 4.6
GOST 10181.0-81 Concrete mixtures. General requirements for test methods, clause 4.1
GOST 10181.2-81 Concrete mixtures. Methods for determining density, clause 4.5, clause 4.6 (Appendix A)
GOST 12730.1-78 Concrete. Methods for determining density, clause 4.6
GOST 18105-86 Concrete. Strength control rules, clause 3.1, clause 4.6
GOST 23732-79 Water for concrete and mortars. Technical conditions, clause 2.5. (Appendix A)
GOST 24211-90 Additives for concrete. Classification, clause 2.3 (Appendix A), clause 2.4 (Appendix A)
GOST 27005-86 Lightweight and cellular concrete. Rules for controlling average density
GOST 27006-86 Concrete. Rules for the selection of composition, clause 3.1 (Appendix A)
GOST 30108-94 Construction materials and products. determination of specific effective activity of natural radionuclides, clause 3.5.

One of the most popular materials in the construction industry is concrete. Without it, to one degree or another, almost no construction can be done, be it on an industrial scale or in the private sector. With the development of technology, varieties of concrete with a certain set of characteristics have appeared. One of them is polystyrene concrete, which is gaining increasing popularity among consumers, including at FORUMHOUSE.

In this article we will look at:

what is polystyrene concrete?
varieties, scope of application, characteristics of this material;
production;
as used by our craftsmen.

Polystyrene concrete – raw material base, properties

Polystyrene concrete (PSB) is an especially lightweight concrete with a porous structure, produced on the basis of a cement binder (usually Portland cement) with porous granular aggregate (foamed polystyrene). The permissible bulk density of granulate is up to 15 kg per cubic meter of concrete, under special conditions up to 20 kg/mᶟ. The size of the granules (fraction) depends on the brand and class of concrete and ranges from 0.7-5.5 mm, maximum - 10 mm (thermal insulating PSB of low grades).

Air-entraining substances and various modifying additives are also added to the solution, improving the properties of both the mixture during use and the finished concrete during operation. Air-entraining additives, such as SDO (wood saponified resin), are necessary to give the cement stone a porous structure not only due to polystyrene beads, but also due to the formation of closed air cells.

They prevent the floating of granules, ensuring the homogeneity of the solution and preventing its separation into fractions.

Teplodec FORUMHOUSE Member

Wood saponified resin is needed to enrich the solution with air pores, and is also introduced into the polystyrene concrete or expanded clay concrete mixture to prevent delamination (floating of granules). With the addition, a homogeneous solution is obtained.

This structure provides PSB with relatively low mass and density, and minimal thermal conductivity.

And given the constant rise in energy prices, an increasing number of self-builders, when choosing wall materials, prioritize the insulating ability of enclosing structures of relatively small thickness (about 30 cm). In addition to its light weight and ability to retain heat, polystyrene concrete has other positive properties:

Fire resistance - despite the large volume fraction of polystyrene in the composition, it is a low-flammable material (G1), since the granules are located inside a cement “case”.
Biostability - the building material is not susceptible to pathogenic microflora (mold, fungus) and does not rot.
Sound insulation - air pores and polystyrene granules dampen sound, and together with thermal insulation, sound insulation is also obtained.

There are often accusations of increased hygroscopicity, complexity of subsequent processing, lower strength and low vapor permeability compared to conventional concrete. But these are, rather, the properties of the material, and not its disadvantages; waterproofing and finishing protect it from moisture; there are a lot of materials on sale for such bases, and the strength is selected based on the task at hand. If you don’t try to build load-bearing walls from the heat-insulating variety of PSB, the house will not collapse. Low vapor permeability, characteristic of all polystyrene-based derivatives, is offset by a good ventilation system.

Another thing is that everyone chooses the material that is suitable for themselves, which has certain disadvantages, and PSB is no exception.

Types, characteristics of polystyrene concrete, application

Depending on the formulation and proportions of the incoming substances in the solution, several varieties of PSB are obtained, with different brand indicators; these characteristics determine the scope of application.

Thermal insulating PSB - used for insulation of load-bearing and frame structures, attics and roofs (density D150-D225, strength from M2).
Thermal insulating structural PSB - used for lintels over door and window openings, in thermally efficient external walls as a non-load-bearing filling (density D250-D350, strength from B0.5).
Structural and thermal insulating PSB - used in the manufacture of long lintels over openings, as a wall material in low-rise construction (density D400-D600, strength from B1.5).
Prefabricated products from PSB - wall blocks, slabs, reinforced concrete elements, manufactured on special equipment. The density of non-load-bearing elements is D250-D400 (strength from B0.5), self-supporting - D350-D450 (strength from B1.0), load-bearing - D450-D600 (strength from B1.5).
Monolithic PSB is a self-mixed or factory-made mortar used in various structural elements (filling of floors, screeds, floors on the ground, walls). The ratio of density, strength and scope of application of monolithic PSB is similar to the parameters of the previous version. In recent years, it has become increasingly popular among private owners to build monolithic houses made of polystyrene concrete with their own hands.

The compressive strength class, tensile strength and frost resistance grade (the number of complete freezing-thawing cycles without changing the characteristics) of PSB directly depend on its density. Quartz sand is added to the solution for the production of heat-insulating-structural and structural-thermal-insulating varieties. Together with an increased proportion of binder, this makes it possible to achieve high density and strength. The most important characteristics affecting the scope of application are shown in the table.

Source – GOST R 51263-12 “Polystyrene concrete. Technical conditions".

Production of polystyrene concrete

The technology for producing polystyrene concrete was invented and tested back in the fifties and sixties of the last century, but was not widely used then. This was explained both by the rather costly production cycle and by the insufficient strength of the resulting stone, which did not meet the standards of that time. And there was no such need for insulation; brick or panel houses were built everywhere, without thinking about such “high” categories as thermal conductivity and energy efficiency.

Today, polystyrene has dropped significantly in price, the grade of stone produced has increased, foaming agents and modifiers can be purchased at almost any hardware store, and the energy saving parameters of a family nest directly affect the budget. Therefore, the popularity of polystyrene concrete has increased sharply.

The production of polystyrene concrete can be carried out both on an industrial scale, at specialized enterprises, and in a handicraft version - with your own hands for your own construction site.

But if an ordinary self-mixer can be mixed with a shovel in a trough, some manage to pour dozens of cubes of foundation in this way, then to prepare PSB it is necessary to have a concrete mixer. The composition and proportions of the solution depend on what density (grade) is expected to be obtained. This could be a recipe like this.

In order for the mixture to be as homogeneous as possible, it is important not only to correctly select the ratio of binder, fillers and additives, but also to the sequence of loading into the drum. In most cases, the following algorithm is justified:

loading PVG (foamed granular polystyrene), pouring a small amount of water (1/10 part) with modifiers;
stirring the contents (30-60 seconds) so that the granules are moistened;
introduction of cement (and sand, if we are talking about thermal insulation, structural and structural PSB);
introduction of water (8/10 parts) with a modifier;
introduction of the remaining part of the water with an air-entraining additive diluted in it (SDO, other ready-made foaming agents, liquid soap, dishwashing detergents);
stirring the solution for 3-5 minutes until a homogeneous, workable mixture is obtained.

In order to obtain blocks from a self-mixing solution that are close in performance to the factory ones, a special installation is required, which minimizes the expected benefit if production is not established afterwards.

Therefore, it is more common to pour a monolith into removable or permanent formwork, well masonry, as well as pouring screeds, subfloors and creating thermal insulation contours. Since granules and pores provide poor protection against shrinkage and cracking, it is recommended to use fiber as a reinforcing additive if these phenomena are critical for the structure.

Experience of FORUMHOUSE participants

Our craftsmen also managed to appreciate the advantages of lightweight concrete with polystyrene filler; we will consider the two most common methods of application - insulation and floors on the ground.

Insulation

One of our craftsmen used heat-insulating monolithic PSB of his own production for all his structures.

mobster Member FORUMHOUSE

More than two hundred cubic meters of polystyrene concrete were cast. Frame garage box 140 m² (walls 20 cm and ceiling 20 cm), floor and ceiling of the house 9x14 m (floor and ceiling, thickness 50 cm), frame bathhouse 5x5 m (walls 20 cm and ceiling 20 cm).

An ordinary “pear” concrete mixer, instead of SDO - simple liquid soap, it is not only easier to buy it in a five-liter canister in any hypermarket, but also a solution with such an additive, according to the craftsman, has “better wettability and workability.”

mobster Member FORUMHOUSE

Ingredients for the SBR-132 mixer: 6 plastic buckets of crumbs (12 liters each), plus half a bucket of cement, plus water, plus a soap cap from a 5-liter plastic bottle. Pour in 2 portions, help with mixing with a stick, against rotation.

The goal was not to obtain a self-supporting or load-bearing monolith, only a heat-insulating one, so the density is minimal, like the brand - about M100. According to the standards, this is not enough even for insulation, and it makes sense to slightly change the proportions, increasing the share of cement, but over four and a half years of operation, this PSB has shown itself to be excellent. To this day, pieces from the test pour “are deliberately lying around in the yard in the rain and snow, but no deterioration in performance has been noticed, the fragments do not crumble, do not crumble, do not crawl.”

Polystyrene concrete floors

This method is chosen when you want to get an insulated base without using slab insulation. The minimum load is a bonus.

Teplodec FORUMHOUSE Member

Instead of a layer of EPS and heavy concrete, we use PSB: sand preparation of at least 200 mm, polyethylene film 100 microns, polystyrene concrete D400, layer 100 mm (for the Samara region). If a soft finishing coating is planned on top of the PSB - self-leveling floors or cement-sand screed of small thickness. You can order a ready-made solution or make it yourself, purchasing only foamed polystyrene granules and SDO.

Today, builders are increasingly abandoning the use of traditional building materials in favor of more modern products - polystyrene concrete and expanded polystyrene concrete. This is not surprising, because with the same strength characteristics and durability, they are characterized by lower cost and a number of other advantages. It is also worth noting the ease of use of these materials. Even an inexperienced builder can make polystyrene concrete with his own hands.

However, before we begin the production of this material, let’s consider how polystyrene concrete differs from expanded polystyrene concrete.

Is there a difference between polystyrene concrete and expanded polystyrene concrete

Both of these materials are made using the same technology: from lightweight composite mortars consisting of cement, sand, water and plasticizers. The differences are only in additional additives.

Expanded polystyrene concrete contains special PVG granules of various sizes, due to which the frost resistance of the finished product increases. Based on this, this composition is considered warmer than conventional polystyrene concrete, which does not contain foam.

Healthy! Depending on the diameter of the fractions of polystyrene foam granules, the density, stability and thermal conductivity of the finished material changes.

However, even without special foaming granules, this material compares favorably with aerated concrete and foam concrete blocks and is successfully used in construction.

Advantages of polystyrene concrete

Among the main advantages of this construction raw material it is worth highlighting:

Low thermal conductivity. Lightweight concrete is used for insulation work, as it conducts heat poorly.
Ease. Due to their low weight, structures made from this material have minimal shrinkage.
Durability. The service life of products made from this material is up to 100 years.
Fire resistance. Lightweight concrete tolerates high temperatures well (corresponds to flammability class G1).
Safe for the environment.
Good sound insulation.
Ease of processing with various construction tools. If you made polystyrene concrete blocks with your own hands and calculated their dimensions, then, if necessary, they can be drilled, sawed, milled or fastened with nails.
Resistance to cracking.
Low water absorption.
Non-flammability.

When manufacturing products from this material, you must adhere to certain requirements and recommendations.

Composition and optimal proportions of polystyrene concrete

The production and pouring of blocks is carried out using standard technology, which implies strict adherence to the proportions and sequence of mixing the ingredients. Depending on the ratio of different components, the thermal insulation properties and strength of the finished products will change. It is also worth paying attention to the diameter of the PVG concrete granules (if you plan to make expanded polystyrene concrete) and take into account the marking of the cement.

Before starting construction work, determine exactly what functions elements made of lightweight concrete should perform, and based on these requirements, calculate the required amount of materials. This will avoid costs associated with the appearance of surpluses after completion of work or delays in construction due to downtime waiting for the delivery of the missing amount of raw materials.

To obtain different brands of mixtures, consider the following proportions of components (based on 1m3):

Brand of mixture	Brand and quantity of cement	Polystyrene	Water	Other components
D200	160 kilograms of M400 brand	8 kg	100 liters	1 kg saponified wood resin
D300	160 kilograms of M400 brand	9 kg	95 liters	75 kilograms of sand, 5 kg of latex
D400	160 kilograms of M300 brand	10 kg	115 liters	110 kg sand, 4 kilograms latex
D500	215 kilograms of M300 brand	11 kg	130 liters	180 kg sand, 5 kilograms latex

It is possible to add additional strength to a structure made of polystyrene concrete by adding reinforcing fiber to the composition, which allows minimizing microdeformations during operation under conditions of significant temperature fluctuations.

Healthy! To give the material additional water-repellent characteristics, experts recommend adding tar to the solution.

Required Tools

In order to prepare a solution of lightweight concrete at home, you will need the following tools:

A concrete mixer, or any container in which you can mix it manually (with a garden shovel or hoe) or using a drill with a specialized attachment.
Components for preparing the solution, according to the table.
A bucket or shovel that you will use to measure out the ingredients.
Molds for the production of blocks. You can make them yourself, for example, by pinning old boards together and treating the inner surface of the resulting matrix with machine oil.

Work order

To prepare a mixture using granulated polystyrene, you must perform the following steps:

In a concrete mixer or container for preparing the mixture, mix the cement in the required proportion.
Add sand, which must first be sifted through a sieve.
Add polystyrene in several stages. Before adding the next portion, it is necessary to bring the solution to a homogeneous mass.
Mix in plasticizers and other additional additives.

The production of polystyrene concrete is clearly shown in the video:

Attention! The finished mixture should come out plastic - not dry and not liquid.

Formation of polystyrene concrete blocks

As mentioned above, molds for filling can be made from scrap materials. When putting together a matrix, it is necessary to control the size of the cells so that all finished products are the same. If the blocks are poured on a flat surface, then there is no need to seal the bottom of the molds.

When preparing the matrix, consider the standard sizes of building blocks:

length – 595 mm;
thickness – 375 mm;
width – 295 mm.

To form products, it is necessary to fill the matrices with the prepared solution and leave them to harden for at least a day. Hardening time may vary depending on air temperature, humidity and activity of the binder materials.

After hardening, the finished blocks should sit for two to three weeks in a cool place with low humidity.

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Polystyrene concrete is a popular building material, which has high thermal insulation and strength properties. It is used for various purposes, from building walls to insulating floor coverings. Due to the simple technology for manufacturing polystyrene concrete and minimal costs, the production of the material is becoming a popular area in private business.

Making the solution

The topic of producing polystyrene concrete with your own hands arises among many developers, especially if it is necessary to create products for insulation and wall arrangement.

The solution contains a cement mixture and granulated polystyrene foam (foam balls). They are characterized by high thermal insulation properties and provide a high degree of thermal protection. Plasticizers are also added to the composition to increase the strength and reliability of the final product.

And making polystyrene concrete yourself has a lot of advantages, since it allows you to gain useful experience and reduce the financial costs of implementing a construction project.

Properties and purpose

The characteristics of polystyrene concrete take into account its lightness and practicality. This composite material is produced using simple technology with minimal financial investment.

Characteristics

Polystyrene concrete belongs to a group of composite building materials based on Portland cement or its varieties, silica filler, and a porous component.

The manufacturing process involves a uniform combination of raw materials, including:

Cement mixture.
Sand.
Water.
Granular polystyrene.

The solution is placed into prepared forms or formwork at the construction site. To create high-quality material, you can use simple mixers.

The main properties of polystyrene concrete include:

Long service life - more than 100 years.
Compliance with environmental safety standards.
High degree of vapor permeability.
Flame resistant.
High moisture- and frost-resistant properties.
Good noise insulation parameters.

The list of performance characteristics is as follows:

Manufacturability - due to the light weight and correct geometry of the blocks, creating walls and ceilings based on them is quite simple and quick.
Thermal insulation properties - a wall structure 30 cm thick can retain as much heat as a 180 cm brick wall. Thermal conductivity values vary from 0.7 to 0.1 W/mS. This helps reduce thermal energy costs by 5 times.
Vapor permeability. Due to good moisture and air permeability, walls made of polystyrene concrete can “breathe”, which ensures stable humidity regulation.
Durability - with use, polystyrene concrete blocks acquire additional strength. The declared service life exceeds 100 years.
The temperature range at which the material is allowed to be used varies from -60...+70°C.
Affordable price - 1 sq. m of polystyrene concrete walls will cost much less than the other option.
Thermal inertia - buildings warm up effectively, while their cooling takes a long period of time.
Environmentally friendly - since cement, water, tree resin and safe polystyrene are used to produce the material, the final product meets all environmental requirements.
Flammability class - in terms of fire safety, polystyrene concrete belongs to class NG1 (non-flammable). The material is not afraid of the influence of open fire, since when ignited, the surface granules begin to evaporate.
Weight - blocks measuring 200x300x600 mm weigh no more than 18 kg. This characteristic ensures high laying speed and reduced labor costs.
Strength indicators - a wall 30 cm thick can withstand a distributed load of up to 35 tons per linear line. m.
Waterproofing properties - the material absorbs no more than 4% moisture, which is 4 times less than brick or wood. The likelihood of fungi formation is virtually eliminated.
Noise insulation - a 30 cm wall can absorb more than 70 dB of sound.

Application area

Before you start producing polystyrene concrete blocks with your own hands, you should consider the main areas of their application. Such structures are in demand when arranging screeds or internal partitions, erecting walls and insulating buildings for various purposes.

The material is also used in the production of facade panels or liquid solutions for pouring monolithic objects.

Advantages

The advantages of polystyrene concrete products include the following points:

Products made of polystyrene concrete do not require additional insulation with foam plastic or mineral wool, since they are characterized by high thermal insulation properties.
Sound and heat insulation are included in the list of key advantages due to which people choose polystyrene concrete - the thermal conductivity of the material is quite low, since there are practically no seams when laying it. The declared sound insulation is 37 dB for a wall with a thickness of 100 mm. Connecting the elements requires the use of special glue.
Processing the material is quite easy and comfortable. At the same time, independent production is characterized by low material consumption and reduces the need for solution by 70%.
Installation work does not require special skills and is completed in a short time. Due to their low weight and dimensions, transportation, fastening and other actions with blocks are simplified.
Improved resistance to negative environmental influences. The products are not afraid of moisture, freezing temperatures, mold or mildew.
The service life of the material can exceed 100 years. Thanks to this advantage, it is very popular and is used in various spheres of human activity.
The structures at the base comply with modern standards of environmental, sanitary and hygienic safety.
Processing the surfaces of products does not require special effort or skills.

Flaws

However, in addition to its advantages, expanded polystyrene concrete can also have important disadvantages. Among them:

Low fastening strength. To install dowels and anchor fasteners, you will need to use the M150 grade. If you miss this moment, the element can be removed by hand. Special anchors and dowels for polystyrene concrete are available for sale.
Degraded density. This characteristic complicates the process of installing windows and doors, which can cause the material to deform and the fittings to sag. If the installation technology is not followed, the fasteners will become very loose during use.
Poor adhesion of elements with a low content of polystyrene granules in the composition.
The need for finishing work both outside and inside the building. All block surfaces require additional plastering, but many owners claim that such material does not adhere well to plaster and the walls have to be treated. For best results, it is recommended to make a plaster layer of 1.5 cm on the outside and 2 cm on the inside.
Vulnerability to fire. Without proper treatment, the blocks become a brittle material that quickly ignites.
Insufficient vapor permeability. In this indicator, the material is inferior to aerated concrete or, which is why the microclimate and humidity inside the building are maintained, and the walls stop “breathing.” To prevent negative consequences, it is necessary to equip a functional ventilation system.

Materials for production

The preparation of polystyrene concrete involves the use of a cement mixture and granulated polystyrene (it can be replaced with polystyrene foam). Such raw materials are characterized by high thermal insulation properties, which contribute to reliable protection of the building from freezing. Frost resistance indicators depend on the density of the concrete mixture and the main additives.

The list of necessary components for production looks like this:

Cement mixture grade M400. If you use a higher grade composition, the solution must be diluted with sand in a 2:1 ratio.
Expanded polystyrene. The component is sold in construction hypermarkets.
SDO is a special additive that adds air to the mixture and promotes the appearance of air bubbles, which increase thermal insulation.
Plasticizers. The concentration of these additives in the composition is determined by the characteristics of the mixture.

Equipment

To independently produce polystyrene concrete blocks, you need to prepare special equipment. Its type is determined by the volume of products that need to be produced.

So, the following options apply:

Conveyor line. It is characterized by complete automation and practically does not require the involvement of human power. Finished parts are characterized by correct geometry and high performance properties.
Landline line. Refers to budget equipment, but requires the intervention of workers.
Compact units. Designed for the development of private business. Their productivity reaches 30 m³ per day.

The most budget-friendly option is a set of a concrete mixer, raw materials and molds where the mixed mixture will be placed.

If it is necessary to produce more than 25-30 m³ of blocks per day, you will need to purchase a steam generator that will facilitate uninterrupted loading of the mixture.

Cement proportions

The proportions per 1 m3 for the production of polystyrene concrete are as follows:

840 liters of foamed and treated granules.
200 kg of cement mixture.
100 liters of water.

The final weight of polystyrene concrete depends on the proportions used. In most cases, it is customary to use this ratio of mass and proportions.

How to do

Having understood what expanded polystyrene concrete is and how to independently calculate its proportions, you can move on to production work.

Recalculation of volumes

The specified recipe was developed for large-scale production, and the number of components is based on 1 m3. When making an individual composition, you will need to recalculate the volumes.

In most cases, the consumption of the cement mixture is indicated in kilograms, and other additives - in volumetric units. Different units of measurement make the job more difficult for inexperienced beginners.

When manually mixing solutions or using a concrete mixer, a bucket is used for convenient dosing of components. A 10-liter container can hold up to 12 kg of cement.

Mixing sequence

Work begins by placing the entire volume of polystyrene into the concrete mixer drum. Next, a plasticizer or any detergent is added to the water and poured into the device.

After waiting until the granules are saturated with the solution, which will ensure proper adhesion, you need to pour all the cement and water into the drum. Next, the composition is diluted with an air-entraining component and mixed for 2-3 minutes.

Using this technology, you can create a high-quality and reliable solution that will be used for a wide range of tasks. However, you can purchase bags of ready-made polystyrene concrete and simply mix them with water in the correct proportions. On sale in Moscow stores you can find sets of material that differ in density and performance properties.

The dry mixture already contains plasticizers, and granulated polystyrene is saponified.

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