What is CLC ? CLC is called as Cellular Light Weight Concrete and it is also called as Foam Concrete.

Cellular Light Weight Concrete (CLC) is a version of light weight concrete that is produced like normal concrete under ambient conditions. CLC Blocks are a cement-bonded material made by blending slurry of cement. Stable, pre-formed foam manufactured on site is injected into this slurry to form foam concrete. Fresh foam concrete looks like a milk- shake and the volume of slurry in the foam dictates the cast density of the foam concrete. Are you worried about rising construction costs of projects ? If yes, then CLC blocks is your answer. CLC blocks are a cement-bonded material made by blending slurry of cement. Stable, pre-formed foam manufactured on site is injected into this slurry to form foam concert. Fresh foam concrete looks like a milk-shake and the volume of slurry in the foam dictates the cast density of the foam concrete. Why should a CLC Block Plant Be setup ? Low Investment Quick returns Future product for Construction Industries Green Product Less competition in market Can earn more percentage of profit Easy to handle operations of the plant and can be owned without major engineering expertise Only 10 HP Power is required to run the plant Only 6000 Sq Ft area is required to setup a plant

Advantages Light in Weight : CLC blocks are very lightweight with density ranging from 300 to 1800 Kg/m3. Three times less weight then clay or fly ash brocks. Eco friendly : CLC blocks are Environment-friendly. Foam concrete is eco- friendly material as fly ash and other industrial waste material are used in part of manufacturing blocks to protect the environment. The production process of CLC or its use does not release any harmful effluents to ground, water or air. CLC, due to its low weight is ideal for making partitions. The use of CLC for this purpose will reduce the need for plywood partitions. This consequently will result in reduction in deforestation and will benefit environment. Sound Insulation : CLC Blocks are excellent for Sound insulation which keeps the house cool in Summer and warm in Winter saving energy/electricity for cooling and heating. It is possible to achieve even higher values depending upon the thickness of block. Thermal Insulation : Thermal insulations as a 100mm thick CLC wall, the equivalent thickness of dense concrete wall would have to be more than 5 times thicker and ten times heavier. Lower Water Absorption : The water absorption of this material in relatively lower than any other materials. This compares much better than concrete 50% and ordinary brick, which has water absorption of around 50% to 80%. The low water absorption property of these blocks will help to reduce the cracks in the walls.

Fire Protection : Foam concrete blocks offers grate fire protection. With a just 100mm thickness of wall with density of 1000 kg/m3, offers fire endurance for heat transmission for 4 hours without releasing any oxic fumes during the fire. Fire rating of cellular concrete is far superior to that of brickwork or dense concrete. Easy to Handling : Foam concrete blocks are easy and quick to install, thus minimizing construction costs. They require no minimal maintenance, which reduces long- term costs. Foam concrete blocks are saving in cement, sand, water, labour, energy & time.

Applications Acoustic construction Precast exterior walls Roof insulation and waterproofing Green construction Additional floors to existing structure Building material for highrises Air-conditioned buildings Low cost housing Subways

Raw Material

Procedure of Making CLC Aqueous foam is produced from the foam generators (IFG) and injected into slurry of cement, fly ash and water in foam concrete mixture (IFM). It creates many small air cells which are uniformly distributed throughout the concrete and create cellular from 300kg/m3 to 1800kg/m3 with compressive strength between 5kg/cm2 to 200kg/cm2. The volume of air cells in foam concrete determines the density and strength. The final mixture is then used for different applications without any vibration or compaction. Fly ash which is a waste-product at thermal power stations. The foam concrete is thus a green building material.

Comparison between CLC blocks and bricks

Parameters Basic raw materials Dry density kg/m3 Ageing Sound insulation Eco friendliness

CLC Blocks Cement, fly ash, water and foam 600/800 Gains strength with age (Like conventional concrete) Superior - Pollution free - No primary energy consumption - Consumes fly ash (an hazardous industrial waste material) High thermal insulation Compressive strength is more than other bricks. CLC is a light weight block where water absorption is less as compared to redbrick and fly-ash brick

Burnt Clay Bricks Top agricultural soil, primary energy input 1900 No Normal - Creates smoke - high energy consumption - wastes agricultural land - soil erosion - banned in more and more countries Normal thermal insulation Compressive strength is less Redbricks and fly-ash brick absorb more water than CLC blocks

Thermal Insulation Compressive strength Water absorption capacity

CLC Block sizes

Size in MM

No of Block in one m3 83 55 41 33

600 x 200 x 100mm 600 x 200 x 150mm 600 x 200 x 200mm 600 x 200 x 250mm

Comparison between CLC Blocks and AAC Blocks

Parameters Basic raw materials

CLC Blocks Cement, fly ash, water and foam

AAC Blocks Cement, lime, specially grinded sand, aeration compound, high primary energy input Produced only in well established plant, equipped with steam boiler and high pressure auto-claves 400/ 700 20- 40 Non-load bearing panels and blocks No aging Loses strength, if not protected against humidity 0.09-0.15 (depending on density) - Pollution free - High energy consumption

Production process and setup

Using ribbon mixer and foam generator

Dry density kg/m Compressive Strength kg/cm2 Usage

600/ 800 30- 40 Thermal insulation , partitions, non-load bearing blocks Gains strength with age (like conventional concrete) 0.09 0.12 (depending on density) - Pollution free - No primary energy consumption - Consumes fly ash (an hazardous industrial waste material)

Aging

Thermal conductivity (W/mK) Eco friendliness