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MearlCrete is an organic protein based performed cellular concrete foam.  Aerix Industries developed and supplies the product.  CJGeo is an Aerix Industries factory-trained installer.  We are based in Virginia and install cellular concrete throughout the eastern United States.  Cellular concrete can be used for a variety of applications, such as:

MearlCrete Mix Designs

MearlCrete being used for pipe abandonment

Pipe abandonment using MearlCrete cellular concrete.

MearlCrete is primarily used in the roofing and lightweight floor industries where relatively thin placements are most common.  In geotechnical and utility applications, Aerlite, Aerlite-iX and Aquaerix are more commonly used.  However, every preformed cellular concrete foam has its place in all industries and applications.

Typical densities for MearlCrete range from 20 lb/cuft to 90 lb/cuft, with associated strengths ranging from 50psi to 1500psi.

To create lightweight cellular concrete using MearlCrete, the concentrate is mixed with water a specific ratio.  The concentrate/water blend is then processed through a foam generator.  The foam generator aerates the mixture, which causes it to expand.  

Depending on the batch method, the expanded preformed foam can be introduced to a transit mix truck containing a set amount of slurry (batch-generation), or injected into a concrete hose to mix with slurry being continuously pumped (continuous generation).  Batch generation is typically used for low volume projects (fewer than 10 cubic yards).  Continuous generation is used for larger volume placements.

MearlCrete Applications

MearlCrete is primarily used in thin placements.  Heat of hydration of the cement in cellular concrete can affect the dimensional stability of the material during initial curing.  This isn’t a problem in thin lifts (less than 24″) or if the wet cast density is relatively low.  However, if thicker lifts are required, a synthetic preformed foam such as Aerlite is typically used.  Aerlite-iX, which is an organic/synthetic blend, can also be used for thicker lifts.  Aquaerix can routinely be used for lifts up to 8′ deep.  

MearlCrete can’t be used to create pervious cellular concrete.  In cases where pervious cellular concrete is required, we use Aquaerix.  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.  

Speak With An Expert

Questions about mix designs or application of cellular concrete?  

Kirk Roberts, c: (757) 592-0452, kirk@cjgeo.com