Cellular Concrete Truck Batch Generation Process
With batch mix cellular concrete generation, slurry is delivered to the job by transit mix truck. The slurry load size is specified based on the desired wet cast density of the mix. For example, for a 30PCF mix, to create 10 cubic yards of cellular concrete the transit mix trucks deliver about 2.5 cubic yards of slurry to the job.
Cellular concrete batch equipment is then used to introduce preformed foam into the transit mix truck’s drum. A few minutes of gentle mixing causes the preformed foam to blend uniformly with the slurry, resulting in 10 cubic yards of homogenous cellular concrete mix, ready for placement. For the example 30PCF mix, about 7.5 cubic yards of preformed foam would be added to the drum of the transit mix truck.
Cellular Concrete Truck Batch Generation Equipment
We use a tank-based system for generating truck-batched mixes of cellular concrete. The tank system is made up of two 80 gallons pressurized tanks, which are filled with a blend of foam concentrate and water. The tanks are connected to a foaming chamber which turns the concentrate/water mixture into preformed foam as it’s sprayed into the transit mix concrete truck.
Advantages of Truck Batch Generation
Batch generation achieves very uniform material from truck to truck. On sites where slurry supply is inconsistent, and especially when volumes are small, batch generation allows for stop & start onsite generation of cellular concrete. For example, on a lightweight foamed concrete project in Norfolk, VA with a very long, narrow site, CJGeo generated nearly 1400CY of 75lb/cuft sanded LWFC using truck batching generation. The average variance of wet cast density between trucks was less than 0.5lbs/cuft. Due to traffic, supply of slurry was stop & start. Had continuous generation been used, the continuous generation equipment would have required tuning very frequently, which would have caused quality control/consistency problems.
Due to an unusual layout, average daily pours were only about 80CY, so cellular concrete truck batch generation was the most economical & practical approach.