Construction Industries

PROFO

Protein based foaming agent for CLC (Cellular Lightweight Concrete)

PRODUCT PROFILE OF PROFO (CONSTRUCTION CHEMICAL) - (TECHNICAL)

Protein based foaming agent (Profo) is concentrated with enzymatic active components,
developed for the building material industry. Diluted in water and processed in a foam generator
with compressed air it produces very fine and stable high quality foam. Depending on dilution and
settings of the foam generator

Our protein-hydrolisation based foaming agent warrants high stability of the foam, successfully withstanding the manifold forces occurring when mixing, conveying (pump-able), casting and during the hydration process. The foam causes no chemical reaction in the concrete but merely serves as wrapping material for the air entrapped. It produces no toxic fumes or emission over its lifetime. Store-life of the foaming agent is guaranteed to be at least 24 months when adhered to instructions (before its integration into the concrete mixtures).

PROPERTIES OF PROTEIN BASED FOAMING AGENT:-

1. Highly Water Soluble and Miscible.
2. Bio – Degradable.
3. Can be easily handled without fear of Toxicity.
4. Dosage requirement is comparatively less which makes it cost effective.
5. Contains Peptides of different molecular weights.
6. Produces stable and homogenous air bubbles.

PHYSICAL AND CHEMICAL PROPERTIES

Recommended:

1 kg * of (Profo) foaming agent, diluted in 40* parts of water
#Note: (*)= Usage of foaming agent varies from 1-1.5 kg, diluted in 25-40 parts of water due to
climatic conditions i.e. Quality of water, Temperature and Wind Flow etc.

Special grades of foaming agent are:
        a. Profo-1000
        b. Profo-800
        c. Profo-600
        d. Profo-400

Relative Technical Specification

Relative Technical Specification

Particulars Profo-1000 Profo-800 Profo-600 Profo-400
Appearance Dark brown liquid Light brown liquid Light brown liquid Light brown liquid
Spl Grade PF42 PF40 PF36 PF30
Sp. Gravity 1.15 - 1.18 1.14 - 1.17 1.12 - 1.15 1.12
pH at 20°C 6.5 - 7.5 6.5 - 7.5 6.5 - 7.5 6.5 - 7.5
Viscosity at 20°C >10 CST >10 CST <10 CST <10 CST
Availability of Chlorides In ppm In ppm In ppm In ppm
Solubility Miscible with water in all proportions Miscible with water in all proportions Miscible with water in all proportions Miscible with water in all proportions
Use of Foaming Agent (Normal Dry Density 750 kg/m³) 1.2 ltr* (diluted in 40* parts of water) 1.2 – 1.25 ltr* (diluted in 40* parts of water) 1.25 ltr* (diluted in 40* parts of water) 1.25 – 1.5 ltr* (diluted in 40* parts of water)

Competitive Advantages of the product

Our Foam advantages at a Glance:

Advantages of (Profo) in comparison to others:

➢ Availability of Chlorides in Profo: Minute ratio (in ppm).

Note#

Applications:

Foam concrete of density between 250 – 550 kg/m3 is primarily used for thermal insulation or fire protection. It uses only cement (or with a small proportion of sand), water and foam and can easily be pumped into moulds/wall of varying orientations. Foam concrete of density between 600 – 800 kg/m3 is used for void-filling, such as in landscaping (above/underground construction), filling voids behind archways and refurbishing damaged sewerage systems, as well as producing masonry units. Foam concrete of density ranging from 800 to 900 kg/m3 is primarily used in the production of blocks and other non-load bearing building elements such as balcony railings, partitions, parapets, etc. Foam concrete of density ranging from 1100 – 1400 kg/m3 are commonly used in prefabricated and cast in place walls, either load-bearing or non-load bearing. It can also be successfully used for floor screeds. Foam concrete of density between 1600 – 1800 kg/m3 would be recommended for slabs and other load-bearing building elements where higher strength is obligatory.

Storage:

Within a temperature range of 0°C to + 50 °C. Ensure containers are not directly exposed to sunlight & heat for a long period. It is unaffected by freeze/thaw cycles.

Packing:

HDPE container of 200 Liters

Caution:

Product Mix

Foam Density:
Recommended weight of foam Minimum 80 g/ltr
# yields approx. 510 litres (variable) of foam at 80 grams/litreCrushed Sand might mechanically destroy part of the foam

Water to process foam Potable, if possible below 25°C
#Captive densities are oven-dry (24h at 100°C)Approx. 25% of the total volume of water (in mix and in foam) in relation to the weight of cement used will crystallize and therefore will have to be added to the dry-weight of the cementand sand used to reach the “oven-dry” density.

Recommended Cement
Portland 53 or higher grade, or similar

Recommended Sand
Washed river sand, Density/Sieve: Up to 1.000/up to 2mmMinimum 15-18% fines Up to 1.200/up to 4 mm.
Up to 1.400/up to 5 mm Up to 1.600/up to 6 mm

Bubble size Formed: Avg: approx.: 0.01 – 0.02 mm (10 – 20 microns)

Stability Time: 1.0 to2.0 hours, depending upon the temperatures and environmental conditions.

CLC Blocks made with (Profo) Protein Based Foaming Agent

CLC Blocks made with (Profo) Protein Based Foaming Agent are competitive with bricks in pricing and offer significant savings for finished structures. Savings in construction cost can be as much as 18% when using CLC Blocks, as compared to brick, after taking into account the resulting savings in gravel, cement, steel, labor, structure, foundation etc.

     • Technology is simple and easy to execute
     • Require minimum skilled workforce and primarily deploying unskilled labour
     • Environment friendly – neither wasting natural resources nor creating pollution
     • Economized on Energy Consumption
     • Result in faster execution
     • Finished dwellings are weather-proof, thermally comfortable and durable
     • Suitable for Hurricane/ Earthquake –proof constructions
     • Converting and make productive use of industrial waste products
     • Cost effective in comparison with conventional alternative

Ecology:

CLC Blocks made with (Profo) Protein Based Foaming Agent are environmentally safe. They are bio–degradable and low toxic to the aquatic organisms.

PERFORMANCE SUMMARY

Appearance
Cellular Light-weight Concrete is very light colored. The addition of foam into the concrete mixture creates millions of tiny voids or cells in the material, hence the name cellular concrete. Although there is no direct path for water to pass through the material, an appropriate coating is required to prevent water penetrating into the CLC material. The quality of CLC production can be controlled accurately at the project site, just like Concrete. The surface finish depends upon the formwork and moulds used during casting.

Structural Capability
CLC, like conventional concrete ages well, increasing its strength by as much as 50% (!) between28 and 90 days after pouring, As long as CLC draws humidity from the atmosphere it will keep on increasing its mechanical properties. Curing takes place within the same period as conventional
concrete. If cast in the evening, the concrete it could be demoulded the next morning. Curing can be speeded up by heat, steam or chemical (accelerators). CLC is an excellent and competitive  material for low -rise, load-bearing construction and outside walls as well as partitioning work in
multi –storied blocks.

Thermal properties
Air is known to be the best insulation material available. Air voids, if smaller than 2mm each,consequently increase thermal insulation substantially. Normal aggregate concrete has a specific thermal conductivity (Lambda) of 2.1 W/mK, compared to 0.405 only for 1200kg/m3 cellular concrete. To offer identical thermal insulation as a 100 mm thick CLC wall, the equivalent thickness of dense concrete wall would have to be more than 5 times thicker (i.e. 500 mm) andten times heavier.

Sound insulation
Due to its high sound insulating properties it is used as a sound barrier between suspendedstructural floors, where its light weight and strength is a added advantage.

Fire and vermin resistance
Fire rating of cellular concrete is far superior to that of brickwork or dense concrete. Just a 100mm thick wall of 1200 kg/m3 CLC, offers a fire endurance (heat transmission) of three hours. Moreover, there are no dangerous fumes or spread of fire as experienced with plywood partitions having rigid (styropore, urethane) insulation material – often the reason for loss of life of entrapped individuals due to toxic fumes during fires. CLC does not harbour or encourage vermin.

Durability and moisture resistance
CLC, like conventional concrete ages well, increasing its strength by as much as 50% (!) between 28 and 90 days after pouring, As long as CLC draws humidity from the atmosphere it will keep on increasing its mechanical properties. As a consequence of closed cellular structure of the material, the water absorption of CLC is lower, being in the range of 5% to 12%, depending on density. But it may require a surface protection to resist moisture penetration, affects of very harsh climatic conditions. Reinforced slabs were produced for tests in CLC of densities between 1000-1400 kg/m3, where the nonprotected reinforcement was covered with 25 mm of cellular concrete. After four months, tests confirmed there was no corrosion on the 1200 kg/m3specimen.

Toxicity and Breath-ability
Our protein-hydrolisation based foaming agent warrants high stability of the foam, successfullywithstanding the manifold forces occurring when mixing, conveying (pump-able), casting andduring the hydration process. The foam causes no chemical reaction in the concrete but merely serves as wrapping material for the air entrapped. It produces no toxic fumes or emission over its lifetime. Store-life of the foaming agent is guaranteed to be at least 24 months when adhered toinstructions (before its integration into the concrete mixtures). However, CLC is a concrete product, and similar precautions should be taken as when handling and cutting concrete products. Personal protective equipment (such as gloves, eye wear, respiratory masks) is required during cutting due to the fine dust that is produced by concrete products.

Sustainability (environmental impacts)
In view the use of flyash 33% (an environment polluting industrial waste) being a major ingredient of CLC, CLC and this being a good substitute of ordinary clay bricks (which use high energy and precious agricultural topsoil) the Govt. of India has given special import duty concessions for specialized equipment. Its low density, good thermal and sound insulation and long life make it a good choice as a construction material.

Buildability, availability and cost
This lightweight concrete has higher consistency due to absence of coarse aggregate (gravel) anda ball bearing effect of the foam on the concrete is of great advantage for it flows by itself into the moulds and shuttering and any cavities, thereby doing away with the necessity of compaction or vibration. CLC is an air-cured lightweight concrete that can be produced at project site, utilizing equipment and molds normally in use for conventional concrete. Utilizing, the most traditional mixers and very successful truck mixers to produce cellular concrete, by installing and integrating a foam generator, into the existing concrete or prefab plants, with little investment

and maintaining the production procedures being followed. However, a full range of stationary and mobile equipment to produce and precisely dose the foam, through a conveying system feeding sand and cement to a mixer, with highly effective horizontally operating screw and integrated concrete pump, could be sourced and setup to increase productivity.

Applicability

The wide range in densities and consequently their different thermal and structural properties make CLC equally suitable for use: –
      • As reinforced load-bearing in-situ walls and roofs in Low Rise Buildings.
      • Even block-work (made from pre-cast blocks produced at the project site or obtained from a pre-casting plant) can also be used for load-bearing low        rise constructions.
     • Non load-bearing internal or external walls in High Rise Buildings.
     • Thermal Insulation of building roofs and walls & roofs of cold storage.

Main Features Of CLC Blocks, Prefab Elements & In-Situ Moulded Housing:-