Aerlite is a synthetic/organic blend protein based preformed cellular concrete foam. Aerix Industries developed and supplies the product. CJGeo uses Aerlite onsite to generate and place cellular concrete. CJGeo is based in Virginia and installs cellular concrete throughout the eastern United States. We install cellular concrete for applications such as:
- Lightweight fill
- Insulating fill
- Annular space grouting
- Pipe abandonment
- Tunnel & vault abandonment
Aerlite Mix Designs
Aerlite is one of the most commonly used preformed cellular concrete foams in geotechnical and utility installations. It can tolerate thick lifts, is resilient during pumping, and has high expansion during generation.
Typical densities for neat-mix cellular concrete generated range from 20 lb/cuft to 80 lb/cuft, with associated strengths ranging from 40psi to 1100psi. Sanded base mix is used to achieve higher densities, but is associated with lower strengths.
To create lightweight cellular concrete, the concentrate is mixed with water at a specific ratio. The foam generator turns the water/concentrate blend into expanded foam. Finally, the foam generator aerates the mixture, which causes it to expand. The preformed foam doesn’t change volume after generation.
The expanded preformed foam is either:
- introduced to a transit mix truck containing a set amount of slurry (batch-generation), or
- injected inline downstream of a slurry pump (continuous generation).
Low volume pours can use batch generation. Larger volume placements require continuous generation. There are two types of continuous generation. Dry batch generation yields higher break strengths. Wet batch works best with small pours.
Typical Applications
Aerlite can be used in relatively thick placements. Heat of hydration of the cement in cellular concrete can affect the dimensional stability of the material during initial curing. Because the foam is based on a synthetic protein foaming agent, it is tolerant of thicker lifts than MearlCrete or other organic protein-based preformed foams. Depending on density and pour volume, lifts up to 5′ thick are possible. Aerlite-ix (non-permeable) can pour up to 20′ deep. Aquaer-ix (permeable) can pour up to 10′ deep.
Aerlite doesn’t make high permeability cellular concrete. Aquaer-iX makes pervious cellular concrete. Aquaerix creates an open cell bubble structure in the cellular concrete, which allows for permeability around 35cm/hr. MearlCrete, Aerlite and Aerlite-iX all create closed cell bubble structures within the cellular concrete, making them impervious.
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