Construction of country houses from aerated concrete blocks: technology features and prices. What can aerated concrete do? How to find out if insulation is required
Aerated concrete, used in the production of blocks for building houses, has high thermal insulation properties. However, in difficult weather conditions, additional insulation will not be superfluous.
How do you know if insulation is required?
- If the aerated concrete used has a density of D500, the thickness of the walls of the house does not exceed 300 mm, insulation is necessary.
- Cement mortar was used as glue for aerated concrete blocks. This material does not have the necessary thermal insulation properties.
The manipulations are first carried out in the interior of the house, only then the insulation of the house from aerated concrete is carried out on the outside. The comfortable temperature in the room depends on the thickness of the insulation layer. The optimal insulating layer is 10 cm.
Insulation methods:
- Internal placement of insulation can reduce the usable living space by at least a little. During the process, a ventilation system must be provided. Otherwise, mold may appear on the walls, and fungus may develop between the layers of insulation.
- Insulation of a house made of aerated concrete with outside carried out more often. Residents note the good heat and sound insulation qualities of the insulation. A layer of insulation protects the wall of the house from the destructive effects of moisture.
How to insulate a house made of aerated concrete?
The most popular insulation options are:
- Mineral wool.
- Expanded polystyrene.
Insulation with mineral wool
The material is durable and has high vapor permeability. The use of mineral wool as insulation will provide comfortable temperature and indoor humidity balance.
The service life of the material is 70 years. Mineral wool is more practical compared to expanded polystyrene. Available in the form of slabs and rolls. Plates measuring 50x100 cm are considered the most convenient to install.
Work order:
- External walls clean from dirt and dust using a brush and metal sponge.
- The insulation is glued using a special glue.
- The material is additionally fixed with plastic dowels.
- After drying, a fiberglass mesh is attached to the wall, which will protect the structure from cracks in the plaster and paint.
- Another layer of glue is applied on top of the mesh.
- After the glue has completely dried, the wall is plastered.
Advantages and disadvantages of insulating a house made of aerated concrete with mineral wool
Pros:
- The room warms up quickly.
- Cools down slowly.
- Condensation does not accumulate on the plane of the external walls.
Cons:
- High cost of insulating material.
Insulation with polystyrene foam
Economical insulating material. Can only be used outside buildings. There are two types of polystyrene foam - penoplex and polystyrene foam.
The cost of expanded polystyrene is much lower than the price of mineral wool. This material does not allow steam and moisture to pass through. For aerated concrete houses with foam insulation, additional ventilation holes must be added.
Expanded polystyrene is attached to the wall using glue, after which it is additionally secured with plastic dowels. Plastering and painting the walls is carried out after the adhesive layer has completely dried.
Work order:
- The walls of the house are cleaned of gaps, dust and dirt.
- The cracks are plastered.
- The surface of the walls is primed.
- After the primer layer has completely dried, the insulation is glued.
- The insulating layer is additionally secured on top with dowels.
- Finally, finishing is carried out using plaster or siding.
Insulation of aerated concrete house under siding
This type of finishing can be done with either mineral wool or polystyrene foam boards. Siding is an additional insulating layer. The advantages of this type of finishing:
- Improving the sound insulation of walls.
- Reducing space heating costs.
- Easy to care for.
- Aesthetic appeal.
- Long service life of the material and absence of deformation if installation rules are strictly followed.
- Affordable cost of materials.
- The structure is lightweight, so the load on the façade of the building is minimal.
- Siding is characterized by non-flammable properties, resistant to weathering and fading.
- Can be installed on buildings of any configuration.
Insulation of aerated concrete walls with facade panels
An excellent option for insulating walls is the use of facade thermal panels made of rigid polyurethane, decorated with clinker tiles.
They are used in the construction of ventilated facades - thus, the walls of the house are protected from external influences and from winds, but do not form an unnecessary barrier and maintain the necessary vapor permeability of the entire wall. The “inside-out” principle when applying these facade panels is fully complied with.
With virtually no visible disadvantages, they have a number of positive qualities:
- Provides reliable wind protection
- They have a minimum thermal conductivity of 0.021 W/(m*L)
- Completely harmless to humans, animals and environment
- Rigid polyurethane panels last from 20 to 40 years
- Strengthened metal profile for reliability
- The overall weight of the structure is reduced by 30% compared to analogues
Conclusion
Aerated concrete is an excellent material for the construction of buildings and structures. The houses it makes are warm and reliable. However, to improve energy-saving qualities, any building must be insulated.
Recognized as the optimal insulating material mineral wool. Expanded polystyrene also has good properties. Compliance with insulation technology will ensure a comfortable temperature in the house and increase the service life of the structure for many years.
Aerated concrete is the stumbling block of a considerable number of construction-related disputes. Despite the battles, many professional builders believe that it is a good, although not ideal, building material. Just like everyone else. To decide to build a house from aerated concrete blocks, you need to remember that the material has many useful qualities and has already become quite widespread.
Selection of wall aerated concrete (gas silicate) blocks Source stroyres.net
A little history
For centuries, people have used natural building stone - tuff - to build houses. It was valued for its lightness, ease of processing and ability to retain heat well. Since the 19th century, scientists have tried to reproduce these qualities by experimenting with concrete mixtures. The consistent work of several researchers is considered important milestones on the path to creating modern aerated concrete:
Engineer Hoffmann(Czech Republic). In 1889, he conducted a series of experiments with cement mortar, adding acids and salts to it. During the solidification process, the released gases formed a characteristic porous structure.
Americans Owlsworth and Dyer. In 1914, they were the first to use aluminum and zinc salts. The reaction proceeded with the release of hydrogen, which formed a homogeneous porous structure. The method laid the foundation for future technology.
Architect Erickson. In 1922, the Swede patented a method for producing cellular concrete using aluminum powder, becoming the godfather of modern autoclaved aerated concrete. The first aerated concrete for the construction of industrial and residential buildings began to be produced in 1929.
Modern house project made from gas silicate blocks Source buildhouse.info
In the USSR, industrial production of cellular concrete was also established in the 30s. The first autoclaved block aerated concrete was produced in Riga in 1937; buildings made from these blocks still stand in the city. In the post-war 50s, aerated concrete helped restore destroyed infrastructure, both in the USSR and in Europe. IN modern Russia The needs for the material are met by more than 80 modern manufacturing plants.
Composition and technology
Aerated concrete is a representative of the category of cellular concrete, building materials, different in properties and operating features. The unifying characteristics are the porous structure, low weight and low density. The following components are used in the production of aerated concrete:
Astringent. Portland cement.
Filler. Quartz sand.
Gas generator. Aluminum powder or paste.
Industrial purified water.
Enhancement Additives. Lime, gypsum, industrial waste (slag, ash).
Autoclave curing blocks Source ar.decorexpro.com
The production of aerated concrete begins with mixing the ingredients and pouring the mixture into molds. The chemical reaction produces hydrogen. The gas increases the volume of the mixture (swells it) and forms pores. After the reaction is completed, the mixture sets, it is removed from the molds and cut according to the standard. Further processing occurs in two ways. Depending on which drying method is used, one of two types of aerated concrete is obtained:
Autoclaved(synthetic) hardening. The blocks gain hardness (steamed) in autoclaves (devices that create high pressure in an environment saturated with water vapor).
Non-autoclaved(hydration, air) hardening. Blocks harden at atmospheric pressure in drying chambers.
Classification
According to the standard, cellular concrete (including aerated concrete) is divided into three types according to its functional purpose:
Structural. Density ranges from 1000–1200 kg/m³.
Structural and thermal insulation. From 500 to 900 kg/m³. Brand D500 indicates that in 1 m³ part of the volume is filled with 500 kg hard material, the remaining volume is air filling the voids (cells).
Thermal insulation. From 200 to 500 kg/m³.
Using blocks increases construction speed Source geo-comfort.ru
Specifications
Aerated concrete serves as an example of the optimal relationship between the main performance characteristics:
Durability. Despite the low density ( specific gravity), the strength is sufficient for the use of aerated concrete in the construction of load-bearing walls.
Lightness. The lightness of aerated concrete is due to porosity, which can reach 85-90% of the volume of the material.
Low thermal conductivity. Good thermal efficiency is also a result of the porosity of the material. Aerated concrete boasts the lowest thermal conductivity coefficient, 0.12 W/m°C (dry).
Homemade mistakes
Having discovered on the Internet many tips for producing aerated concrete with your own hands, and making sure that they are quite feasible, many decide to start their own production. At the same time, home craftsmen do not consider it necessary to strictly comply with technological standards, but they always find people willing to purchase the product at dumping prices.
Small production - no guarantee Source beton-house.com
On our website you can get acquainted with the most popular projects of houses made of aerated concrete blocks from construction companies presented at the exhibition of houses “Low-Rise Country”.
The use of high-quality raw materials and technological equipment in factory production allows us to obtain aerated concrete products with stable physical and chemical characteristics:
Exact dimensions and correct, with minimal defects, shape.
Given physical and mechanical parameters.
Uniform material density, which is confirmed visually (uniform distribution of air cavities).
Chemical inertness of the material, which is confirmed by laboratory control throughout the production cycle.
The conditions of artisanal production cannot provide the manufacturability and control at the level of a modern workshop. Hand-made aerated concrete blocks are distinguishable to the naked eye: the cells (cavities) are distributed unevenly, and the geometry leaves much to be desired. Sometimes such products smell noticeably of chemicals (often lime). Using home-made blocks will most likely reduce the cost of construction, but is guaranteed to become a source of serious problems:
Blocks with arbitrary density and composition have increased fragility and are highly likely to begin to crack in the first year of operation of the house.
Rough seams will cause heat loss Source bg.decorexpro.com
Blocks with non-ideal geometry it will not be possible to place it on special glue; will have to use mortar. Seams with a thickness of 1 to 2 cm will become cold bridges, reducing the thermal efficiency of housing and promoting freezing of the walls.
Blocks with residual undecomposed lime will have a persistent chemical odor (and affect the health of people living in the house). Excess lime can start the process of corrosion of the metal in the wall.
Advantages and disadvantages of the material
A country gas silicate house has the same strong and weaknesses, as the source material. Based on the structure of aerated concrete, many advantages can be highlighted:
Cheapness. Due to the low consumption of cement in the production of products.
Construction speed. The blocks are significant in size and weigh 3-5 times less than a brick of the same volume. This allows you to build 1 m² of wall in 20-25 minutes, which is unattainable in the case of brickwork.
Construction costs. Savings come from rational use labor time and construction materials.
Aerated concrete can be processed manually Source kamtehnopark.ru
construction service of houses from aerated concrete blocks
Low thermal conductivity. According to this indicator, aerated concrete better than brick 2-3 times. A wall made of 37.5 cm thick blocks retains heat as well as 60 cm thick brickwork.
Ease of processing. Blocks can be cut by anyone without any problems hand tools, sawed, milled and fined. This flexibility allows you to create complex architectural projects.
Fire resistance. Aerated concrete is characterized high degree fire resistance and belongs to the flammability group NG (non-flammable). When exposed to a flame with a temperature above 100°C for two hours, an aerated concrete wall begins to lose strength and crack to a depth of 3-4 cm (enough time to leave the house and call the fire brigade). Wooden house During this time it will burn to the ground.
Vapor permeability. High. Due to the presence of interconnected voids, the material successfully regulates the humidity in the room (breathes).
Environmental friendliness. Lime and aluminum powder used in production are converted into inert materials after a gas formation reaction. solids. Therefore, the material, made according to all the technology requirements, does not emit any volatile substances into the air.
This is interesting! On various construction forums you can often find references to a certain table of coefficients of environmental friendliness of materials. There are even some numbers given - for example, for expanded clay this coefficient is 20, for brick - 10, aerated concrete - 2, and the leader and standard is wood - its value is 1. In practice, the existence of such a table is not confirmed in any official document , although if we consider materials specifically in terms of the release of any substances into the air, then there is some truth in such a division.
Durability. In the Scandinavian countries, Germany and France, there are many houses made of aerated concrete, built 40-50 years ago and still showing no signs of destruction. This durability is due to the quality of the factory-made material and installation carried out in compliance with the technology.
Post-war aerated concrete house Source bwncy.com
Frost resistance. Aerated concrete resists cyclic freezing well.
Features of aerated concrete blocks determine the weak points of the structure:
Flexural strength. Aerated concrete is characterized by a relatively low coefficient of ultimate deformation (0.5–2 mm/m). Foundation deformation beyond these limits leads to the appearance of cracks in the wall of the house. The means of combating will be the construction of a solid foundation with monolithic lining or mesh reinforcement, tying the floors and reinforcing the masonry. It is also not recommended to build private houses higher than 3 floors.
Fasteners. Nails, anchors and screws fit perfectly into an aerated concrete wall, but they stay there disgustingly. A characteristic disadvantage of all cellular concrete is corrected by the use of special fasteners for porous surfaces (steel, nylon, frame). You should also pay attention to the installation of windows and doors (if installed incorrectly, they may become loose over time).
Adhesion(clutch with finishing materials). It is not high, so before plastering the wall must be prepared (reinforcement or a layer of primer).
External finishing of the facade with plaster Source hug-fu.com
On our website you can find contacts of construction companies that offer house design services. You can communicate directly with representatives by visiting the “Low-Rise Country” exhibition of houses.
Shrinkage. Shrinkage non-autoclaved aerated concrete reaches 2 mm/m, autoclave - up to 1 mm/m.
In order for the constructed house to serve for a long time and without problems, it is necessary to take into account the characteristics of the material:
Hygroscopicity. A porous wall can absorb and release moisture (like, for example, a wooden wall). To protect the facade from excess moisture, the walls are lined, preferably with ventilation.
Heating. A house made of aerated concrete can significantly reduce heating costs, but it must be taken into account that the higher the grade of aerated concrete, the worse its thermal insulation properties. Energy efficiency can be improved by simple plastering.
Ventilation. Since aerated concrete is quite large building blocks, the likelihood of poor-quality installation increases, even taking into account the excellent geometry of the products. For example, if the glue is too thick, it does not completely fill the space between the blocks and through gaps form. If there is such a possibility, then after construction it is recommended to conduct a thermal imaging inspection of the house to know whether there are joints and seams that need to be sealed.
Aerated concrete cottage with cladding underneath natural stone Source pinterest.ch
Myths about technology
Many have encountered not the most flattering reviews about aerated concrete and operational characteristics houses that had the misfortune of being built from it. Such judgments and conclusions often have little to do with reality and are caused by a misunderstanding of the characteristics of the material and technology. Most often you can hear such “expert” opinions:
Aerated concrete walls are prone to cracking. Cracks can appear not only in an aerated concrete wall, but also, for example, in brickwork. After the examination, we have to admit that in most cases the cause of the defect is not the quality of aerated concrete. Most often, the culprit is a poor-quality foundation, the design of which did not take into account the soil characteristics and location groundwater. Another reason may be reinforcement errors (both walls and foundation). The quality of aerated concrete will play an unfortunate role only if garage-made material was used.
Aerated concrete buildings require insulation. If, when developing a house project, the thickness of wall structures was laid taking into account the standards of SNiP 23-02-2003 (on thermal protection of buildings), additional insulation will not be required. But since aerated concrete houses If the façade needs to be finished, the insulation is often installed at the same time.
Finishing requires the installation of a ventilated facade Source bankfs.ru
Aerated blocks for the home are a very fragile material, which splits when hit by a hammer. The same brick can also be split by applying a certain force. According to SNiP, for low-rise construction(up to three floors) recommended aerated concrete blocks brand D500, which are quite durable and at the same time light and warm. The D400 brand material is more fragile and warm, the D600 brand material is, on the contrary, stronger and colder. Houses built taking into account technological features cope well with the resulting loads, even in seismically active areas.
Aerated concrete absorbs moisture like a sponge, therefore, a newly built facade requires prompt waterproofing. One of the main features of the material is its gas and vapor permeability, which, however, is not very different from the characteristics of wood. Like wood, aerated concrete is able to absorb moisture and then return it, regulating the microclimate in the rooms. Both materials have a humidity corresponding to the humidity of the surrounding air, and since concrete does not dissolve in water, aerated blocks are not in danger. External walls will not be excessively moistened in cottages with year-round accommodation and properly equipped cladding (which does not impede the circulation of moisture).
Video description
About construction from gas silicate blocks in the following video:
The aerated concrete block gets wet and submerged in water, therefore not suitable for the construction of suburban housing. Strange logic, if you remember that the foam remains on the surface of the water, and the brick instantly sinks to the bottom. The degree of water absorption of an aerated concrete wall during operation is in no way related to buoyancy; these are two different characteristics.
Living in a house with aerated concrete walls is dangerous, since the material contains lime and aluminum, and the rooms sometimes smell of lime. These elements are part of the original mixture; then they enter into chemical reaction(reaction of transformation, transformation) with other components. The output is artificial stone, aerated concrete in which there are no original elements. For industrial production Characterized by precise dosage of starting substances and high-quality drying, as a result of which only safe silicates remain in the material. The smell of lime appears in garage aerated concrete when the components are measured “by eye” and more lime is added than necessary.
Design features of a typical aerated concrete project Source stroyres.net
When developing a project country house made of aerated concrete parts are based on the characteristics of the material. To make housing comfortable and durable, the following points are taken into account:
Wall thickness. Determined by constructive necessity. Optimal thickness load-bearing walls in climatic conditions middle zone Russia fluctuates between 300-400 mm, interior partitions - 100-150 mm.
Suitable foundation. For aerated concrete walls, a reliable and stable foundation is important. A monolithic slab base is usually recommended; It is advantageous to use it on various soils.
Video description
About a typical house made of aerated blocks in the following video:
Roof. Pitched or flat, the roof needs proper installation on aerated concrete walls. A lightweight structure with metal tiles, corrugated sheets or bitumen shingles as roofing is preferred.
The need for conservation. Laying of autoclaved aerated concrete is not carried out at temperatures below -5°C. If cold weather sets in, the house is preserved; It is desirable that by this moment it already has ceilings above the first floor. The walls are covered with a waterproofing film, just like pallets with blocks (it is better if they are packed in factory-made shrink tape).
Roof arrangement aerated concrete house Source bankfs.ru
Subtleties of design
Aerated concrete is a material that offers the widest possibilities for architectural solutions; one only has to remember the famous Dancing House in Prague. The following requirements apply to the design of a country cottage made of aerated concrete:
Originality. Details architectural style are able to convey the taste of the owners and emphasize their individuality. An exclusive look is often achieved by combining modern and traditional styles.
Practicality(functionality). Currently, houses are being designed from aerated concrete with a thoughtful layout and with any additions - a garage, a terrace (including on the top floor), an attic, a glazed bay window or a balcony.
Comfort. The concept of comfort can be different, and the interior of a house made of aerated concrete blocks can be decorated in any style, from traditional classic to ascetic minimalist. Often the customer's choice is cozy style country, picturesque Provence or energetic loft.
A modern project with oriental notes Source pinterest.com
Projects and prices of turnkey aerated concrete houses
If you decide to build a house from aerated concrete, its price will in any case be more affordable than a similar brick cottage. Many variables will affect the cost:
Project type. You can buy a popular standard project (with ready-made documentation) or order an individual development that takes into account personal preferences.
Brands of building materials. The price depends on the manufacturer (domestic or foreign) and the volume of purchase.
Complexity of the architectural solution. Determined by the area and number of floors of the project, as well as the type of foundation and roof.
Relief of the site. If there is a slope on the site, the project will have to be modified.
Video description
About thermal imaging inspection of a house made of aerated blocks in the following video:
By choosing to build a house from aerated concrete blocks on a turnkey basis, you will be able to appreciate all the advantages of this service, because from the moment the contract is signed, all current issues related to the construction of the house become the concern of the contractor:
Inevitable improvements and changes to the project.
Geological and geodetic studies of the site.
Selection of workers and quality control of construction.
Construction work stipulated in the contract (from the zero cycle with laying the foundation to laying engineering communications and finishing).
Video description
Today we will discuss how to build an inexpensive house from aerated concrete. How much does a turnkey aerated concrete house cost in the following video:
Of course, you will be able to receive a report at any time or personally monitor how construction is progressing and how the agreed estimate is spent.
Country house made of aerated concrete blocks, individual project Source bankfs.ru
When choosing a construction company, you should focus on the time of its existence, the number and quality of completed projects, and reviews from real clients. Companies with extensive experience have their own design bureau, permanent suppliers and professional work teams of various profiles. Construction companies that care about their reputation act according to a well-established scheme, prefer to maintain optimal prices and often have a system of discounts on materials.
Prices for the construction of country houses from aerated blocks in the Moscow region are as follows:
Area up to 100 m²: on average 2.25 - 3.700 million rubles.
From 100 to 200 m²: 4,150 - 5,200 million rubles.
From 200 to 300 m²: 5,560 - 8,670 million rubles.
Conclusion
When planning to build a country house from aerated concrete blocks, you need to be sure that the housing will delight you with comfort for many decades. Such confidence will be given by high-quality raw materials and reliable construction company, whose specialists know and strictly follow construction technologies.All products made from cellular concrete must be manufactured using the same technology and in the same type of interchangeable forms, using a cutting system in which a raw aerated concrete mass of 5-15 m3 in volume is cut into products of the required sizes.
The following products are made from autoclaved aerated concrete:
Small wall blocks;
- unreinforced large wall blocks;
- reinforced large wall blocks;
- wall panels integrally molded;
- composite wall panels;
- volumetric blocks;
- partition slabs;
- interfloor floor slabs;
- coating slabs;
- thermal insulation boards;
- jumpers;
- acoustic plates;
- decorative plates.
2.1. Small wall blocks
Unreinforced small blocks of aerated concrete are manufactured and accepted in accordance with GOST 31360. They have classes of compressive strength not lower than B1.5 and density grades not higher than D700.
Blocks are made I and II categories.
Size deviation
BlocksIcategories:
Length ±3 mm;
- width ±2 mm;
- height ±1 mm.
BlocksIIcategories:
Length±4 mm;
- width±3 mm;
- height ±4 mm.
Walls made from small blocks are laid using mortars or glue. Aerated concrete blocks can be used to make external load-bearing, self-supporting and curtain walls, as well as internal load-bearing walls and partitions.
For normal operating conditions, blocks must have a frost resistance of at least F 25, for wet conditions - not lower F 35. In areas of the Far North with estimated temperatures below - 40 o C, frost resistance grades should be no lower, respectively F 35 and F 50.
2.2 Large wall blocks
Non-reinforced (according to GOST 31360) include products with maximum dimensions length up to 1500 mm, width up to 1000 mm, thickness up to 600 mm. They are intended for direct installation of large-block and large-panel buildings or for enlarged assembly in panels.
Large blocks are used for the construction of external and internal walls of all types: curtain walls, self-supporting and load-bearing. External wall blocks are recommended to be finished surface layer at the factory and delivered to construction site in finished form.
The frost resistance grade must be no lower than F 25, in wet conditions - F F 35 and F 50.
At blocks I and II categories, the same size deviations are allowed as for small blocks.
2.3 Reinforced large blocks and wall panels
Reinforced large blocks and wall panels are manufactured according to GOST 11118.
Large reinforced block- this is an element with an area of less than 1.8 m2, reinforced with structural and working reinforcement, designed to withstand technological, transport, installation and operational loads. The wall panel can be solid or composite.
A solid external wall panel is a factory-made product with an area of at least 1.8 m2.
A composite wall panel is a panel assembled from initial elements (including large blocks with glue, mortar, by welding steel embedded products or using ties.
The initial element is a reinforced large block, combined into a mounting panel.
Composite panels are more preferable, since only they allow the use of cutting technology, are more crack-resistant, require less reinforcement consumption, and make better use of molds and an autoclave.
To increase crack resistance, prestressed reinforcement can be provided, as well as tension ties used for enlarged assembly and installation.
The density grade of aerated concrete used ranges from D400 to D800, the compressive strength class is from B1.5 to B7.5.
Panels can be hinged, self-supporting or load-bearing. For external longitudinal walls, curtain wall panels should be used, allowing the use of the lightest and most efficient aerated concrete of the D400 brand. Single-row external walls are supplied fully finished with joinery and glazing inserted. The exterior department should provide an expressive architectural appearance of the facade and its durability.
The frost resistance grade for normal operating conditions must be no lower than F 25, in wet conditions - F 35. For conditions of the Far North, respectively F 35 and F 50.
Installation of panels can be carried out using mortar, adhesives (mastics) and dry with the help of elastic gaskets. Self-gripping traverses should be provided as mounting devices. Composite panels are lifted by tie rods, which can be removed after installation. It is recommended to make the joined edges of the panels flat, without ridges and grooves. Blowing and wetting are prevented by sealing with mortar, poroizol and elastic mastics. Anchor connections between panels and adjacent structures should be made without molded embedded parts, and the workability of cellular concrete should be used.
Channels and grooves for hidden wiring and utilities are recommended to be carried out in the factory using electrified cutters and drills. Calculation of wall panels for strength and deformation should be carried out in accordance with STO 501-52-01-2007.
Transportation of panels should be carried out by panel carriers in a state secured from dynamic influences using elastic gaskets. It is recommended to use mounting from wheels. During transportation and storage, panels must be protected from moisture and mechanical damage. Other technical requirements are set out in STO 501-52-01-2007.
2.4 Volume blocks
Volumetric blocks (block rooms) made of aerated concrete are a new progressive type of structure. They are assembled using glue and strands from individual flat elements obtained using cutting technology. The blocks are made room-sized and look like a box closed on all sides. They can be suspended (hung on a frame) or load-bearing. In the first case, the thickness of the internal walls must be at least 8 cm. For load-bearing blocks, the thickness of the internal walls is assumed to be at least 10 cm and the compressive strength class is at least B3.5.
Floor elements in both options must have the same minimum thickness and class. The size of the air gap in the walls and ceilings must be at least 5 cm. It is recommended to make external walls a curtain structure; they transfer their weight to the ceilings and transverse load-bearing walls.
Installation of the blocks is provided dry in order to ensure the possibility winter construction at any temperature. Volumetric blocks are supplied fully finished for installation. Finishing is carried out either at an aerated concrete plant, if it is connected to the construction site by a good road, or at an on-site closed site, where the aggregate assembly of blocks is carried out.
Loading of volumetric blocks is carried out using a balancing beam, ensuring the absence of distortions. The blocks are transported by trailers with a soft platform suspension.
During installation, the blocks are protected from moisture.
2.5 Panels for partitions
Partition panels made of aerated concrete are manufactured in accordance with GOST 19750.
Panels of partitions (non-load-bearing) made of aerated concrete can be multi-row cut or single-row cut.
Reinforced slabs (panels) of partitions are made from aerated concrete grades D400-D800, classes B1.5-B7.5, height per floor, thickness from 8 to 30 cm, width from 60 cm. Reinforced with a central mesh of cold-drawn wire for thicknesses from 80 mm to 120 mm or two meshes for thicknesses from 160 to 300 mm. Frost resistance - no less F 15. In wet rooms, slabs are protected with a painted hydrophobic vapor barrier.
The panels are joined using glues and mastics. They are attached to adjacent cellular concrete structures using nails. Drive pins, dowels, staples and screws. They must be lifted using pincer grips (without hinges).
Delivery and storage are carried out on pallets in bags protected from moisture.
Technical requirements are set out in GOST 19570 and STO 501-52-01-2007.
2.6 Floor panels
Floor panels are manufactured according to GOST 19570 from aerated concrete of classes from B2 to B10 and density grades from D500 to D1200. Their width can be from 600 to 1800 mm. Length 2400-6000 mm, thickness 140-250 mm. With a thickness of 220 mm, they become interchangeable with hollow-core panels made of heavy concrete and can be used in brick standard houses, as well as during their reconstruction. Frost resistance - no less F 25.
Reinforcement can be carried out using prestressed reinforcement (wire or rod), prestressed on cellular concrete or reinforced concrete bars (bar reinforcement).
Embedded mounting loops can be provided if pincer grips and traverses are not used.
During calibration, panels can be used for “dry” installation, i.e. without installing support mortar beds (if the support also occurs on calibrated surfaces). Longitudinal and transverse seams between the panels are reinforced and filled with cement mortar, and reinforcing cages are laid above the supports in the longitudinal seam.
Slots, channels and holes for electrical wiring and utilities can be cut on the construction site using electric cutters, drills, disk or chain saws, as well as hand plows. It is prohibited to hammer concrete with impact tools. Grooves and other weakening should not reduce the load-bearing capacity and rigidity of products below the required values.
The calculation of floor decking is carried out for strength, rigidity and crack opening in accordance with the design standards for structures made of cellular concrete and STO 501-52-01-2007. The maximum design load for a length of 6 m should not exceed 600 kg/m2 (6 kPa) (over dead weight).
Storage and transportation are carried out in the working position (flat) on pads, protected from moisture.
Technical requirements are set out in GOST 19570 and STO 501-52-01-2007.
2.7 Cover panels
Aerated concrete roofing panels are made from concrete of classes from B2 to B3.5, grades D400-D600. Their length is from 2.4 to 6 m, width - from 0.6 to 1.8 m, thickness - from 250 to 400 mm.
To increase the thermal insulation ability of coatings, it is recommended to make them ventilated. Ventilation becomes necessary in panels laid above wet areas, even with a lower vapor barrier.
The frost resistance of the material of ventilated panels must be at least F25, for non-ventilated panels - at least F35, respectively, for the conditions of the Far North - F35 and F50.
Load-bearing coating panels are reinforced based on operational loads (possibly with prestressed reinforcement).
Non-load-bearing panels (laid on a reinforced concrete base) are reinforced to accommodate demoulding and transport loads. The upper plane of the panels (including above the channels that do not extend to the surface) is reinforced with an anti-shrink mesh made of cold-drawn wire with a diameter of 3-4 mm with a cell side of 10-15 cm. Ventilation channels (grooves) in coating slabs manufactured using cutting technology should come to the surface and be arranged by milling.
The minimum cross-sectional area of the channel is 15 cm 2, the maximum step is 20 cm and increases in proportion to the cross-sectional area of the channels. Mounting loops are not provided in case of using pincer grips and traverses.
It is recommended to cover panels with a smooth top surface at the factory with a layer of bitumen or paste over with roofing felt in order to simplify roofing works and reducing moisture during transportation, storage and installation.
In case of calibration of load-bearing panels and supporting surfaces, dry installation is allowed. Anchoring is carried out using strip anchors connected to the supporting structures and nailed to the covering panels. When installing the covering panels, the longitudinal and transverse seams that serve to pass through the channels are monolithic only to the level of the bottom of the channels. Above the supports, reinforcement cages are inserted into the solution of longitudinal seams.
Coating slabs are calculated for strength, rigidity and crack opening in accordance with STO 501-52-01-2007.
Transportation and storage are carried out in the working position, on pads, taking measures to prevent moisture. At the same time, the natural drying of the panels before installation should not be impaired.
2.8 Thermal insulation boards
Thermal insulation slabs are manufactured in accordance with GOST 5742, with dimensions of 100*50*8-24 cm (graded by 2 cm) from cellular concrete of density grades D350 and D400 and compressive strength classes B0.5 and B0.75, respectively.
For civil engineering, taking into account unification, the introduction of cutting technology and achieved quality cellular concrete, recommended dimensions are 600 and 1200 mm in length, 200 and 300 mm in height and 50, 80, 100 and 160 mm in thickness. The compressive strength class for bulk grades D350 and D400 must be at least B1 and B1.5, respectively.
The release humidity of thermal insulation slabs that have the ability to dry out during operation (attic floors, ventilated roofs, external wall cladding, and basement ceilings) should be no more than 25% (by weight). The release humidity of the sealed thermal insulation should not exceed 12%.
Frost resistance should not be lower than 15 (for the Far North - F 25).
Thermal insulation boards must be manufactured using cutting technology, followed by calibration and mounted with glue.
Thermal insulation slabs can serve as formwork panels ( permanent formwork) when concreting monolithic walls, subsequently performing decorative and insulating functions.
Additional insulation slabs are sawed off from the main slabs with a hacksaw, circular saw or chain saw.
Thermal insulation boards are supplied on pallets in bags protected from moisture, but allowing natural drying.
2.9 Jumpers
Aerated concrete lintels are used to cover window and doorways in outdoor and internal walls from cellular concrete. In external walls, lintels are used only in case of block masonry.
The lintels are made of aerated concrete of density grades from D500 to D700, compressive strength classes B2-B5. The thickness of the lintels is 200-250 mm. The length can vary from 1200 to 3600 (graded in 0.3), height - from 200 to 400 mm.
The lintels can be non-load-bearing, in which case they are reinforced structurally, or load-bearing with design working reinforcement in the tension zone. The lintels must have a tempering humidity and frost resistance corresponding to the adjacent wall elements.
The installation of jumpers must be done using pliers (without mounting loops) or manually (for jumpers weighing up to 60 kg).
Support occurs on mortar or adhesive (for calibrated products) beds or reinforced concrete belts. The support depth of the lintels must be at least 150 mm.
The lintels are calculated for strength along vertical and inclined sections in accordance with the design standards for structures made of cellular concrete or STO 501-52-01-2007.
They are transported and stored in working position in bags protected from getting wet.
2.10 Acoustic slabs
Autoclaved aerated concrete has good sound-absorbing ability and can be used as acoustic cladding for indoor spaces in public buildings, restaurants, shops, and playrooms.
Density brand of acoustic slabs D400, strength class not less than B1.5, dimensions 400x400, 450x450, 450x600 mm, with a thickness of 50 mm. Tolerance for length, height and thickness up to 2 mm. Humidity and frost resistance are not standardized. The average sound absorption coefficient in the range often 100-3200 Hz should be at least 0.5. To increase the acoustic properties in slabs 50 mm thick, grooves with a cross-section of 20x20 mm (with an axial step of 40 mm) can be cut, filled with mipore (foam rubber).
The slabs are fastened to the ceiling with staples or screws, and to the walls with glue or mastic. Delivery is made in packages in cardboard containers of 1-1.5 m 3 in one package.
Due to the workability, durability and cost-effectiveness of aerated concrete, decorative slabs with relief and pigment applied to them can be made from it for decorating the interiors of public buildings.
Density grade of decorative boards D500-D700, strength class B1.5-B2.5, length 600 mm, height 200 mm, thickness 50-80 mm. Tolerance for length and height is up to 2 mm, for thickness up to 1 mm. Holiday humidity and frost resistance are not standardized.
Fastening to the walls is done using adhesives and mastics. Delivery is carried out in packages on pallets.
You can vary its size, shape, load-bearing capacity - produce blocks, beams, floor slabs.
Blocks
Today, there are two types of blocks available on the global market for aerated concrete building materials:
– small-piece, up to 625 mm in length and 250 mm in height
– large-format, up to 1200 mm in length and 600 mm in height.
At the same time, the bearing capacity of the blocks is from B 2.5 to B 3.5, density is from 300 to 700 kg/m 3.
With the help of large-format blocks, it is faster to build walls, and the amount of glue is also reduced, since fewer seams are required. Large-format blocks have one “minus” - their laying is carried out only with the help of a crane.
Due to the fact that aerated concrete is an autoclaved cellular concrete, cutting the required block size is not difficult for the manufacturer. The lack of prevalence of large-format blocks in domestic construction practice is due only to the fact that few customers can afford to pay for the work of a crane during the entire period of wall construction.
When constructing walls, building blocks are placed in one row (one after another). Therefore, masonry reinforcement is carried out only along the wall. There is no need for transverse-longitudinal reinforcement, that is, a masonry mesh. Due to the cellular structure of the material and the long length of the blocks (625–1200 mm), reinforcement with a diameter of 8–10 mm is used (for comparison, a brick of 120–250 mm is reinforced with a mesh with a diameter of 4–5 mm).
Wall panels
The use of aerated concrete wall panels is another attempt to build walls as quickly as possible. Aerated concrete, like all concretes, has good compression resistance and poor tensile strength. Therefore, the wall panels are narrow, no more than 600 mm in length, but their height corresponds to the height of the floor - 2700–3000 mm.
But construction cannot do without ordinary blocks, even when constructing walls from panels. Where complex shapes are needed (bay windows, pediments), it is more convenient to use small-format blocks because they are easier to saw and lay.
Beams
The homogeneous structure of aerated concrete (cellular) makes it possible to strengthen its “weak” places. As you know, the weak point of any concrete when working as a beam is the so-called tensile (lower) zone. Therefore, to pass through openings, aerated concrete beams are reinforced with welded mesh reinforcement during the manufacturing process.
The possibility of reinforcing aerated concrete allows its use in beam structures (above-frame, interfloor and attic floors), thereby bringing the entire building structure as close as possible to homogeneity.
The homogeneity of materials (when all elements have the same physical, mechanical and thermal characteristics) during the construction of enclosing structures is one of the components of their reliability.
Coverings and floors
Three types of materials are used as interfloor and attic floors: heavy concrete, solid wood and aerated concrete.
In earthquake-prone areas, heavy concrete floors are supported only by columns and crossbars made of monolithic reinforced concrete. The use of such heavy floors in combination with aerated concrete walls can lead to “crushing” of the latter. Organization of floors from solid wood has limitations: maximum length the span should not exceed 4 meters.
It is very constructive to use aerated concrete as interfloor and attic floors, since it can easily be reinforced. One slab of reinforced aerated concrete can cover up to 6 meters. You just need to keep in mind that to achieve necessary indicators for bending (interfloor floors have a higher index, attic floors have a lower index), the slabs are made quite narrow and thicker compared to reinforced concrete hollow-core floor slabs. In addition, aerated concrete slabs cannot be used to cover ventilated underground floors due to the material’s high hygroscopicity (ability to absorb water). In these cases, reinforced concrete floors are made.
Aerated concrete has several undeniable advantages: it is faster and easier to lay than ordinary efficient brick, and it is warmer. But currently onlyrow blocks length625 mm, others construction materials from aerated concrete have not yet been presented. This is largely due to the fact that the diversity described in the article structural elements made of aerated concrete requires mechanized installation, which increases construction costs.
Aerated concrete seems to be a fragile material only at first glance. In fact, its work in house structures is not much different from ordinary concrete - any type of concrete without reinforcement is fragile. The only point that needs to be taken into account is that cellular concrete, which includes aerated concrete, is reinforced to a lesser extent; therefore, reinforced concrete is still stronger. On the other hand, in each specific case you need to look at whether it is necessary to use “labor-intensive” reinforced concrete or whether the safety margin of aerated concrete is sufficient.
Houses made of aerated concrete
“Construction Rules”, No. 37/ 1 , January 2014
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