CreteFoamer - Cellular Concrete Problems and Solutions

The lists below present only some of the problems which can be solved with cellular concrete. It is focused on building and construction problems, rather than infrastructure and geotechnical problems, where cellular concrete is also used with excellent results. Cellular concrete reduces both the weight and cost of full density concrete, while maintaining many of the properties which make concrete such a valuable construction material. Strength is reduced as density is reduced, so some applications should not be attempted with cellular concrete. On the other hand, cellular concrete provides better thermal insulation than full density concrete.
Problem	Solution
Slabjacking with unknown voids under slab.	Cellular concrete in 40 to 60 pcf will flow easily and penetrate through even the smallest passages to fill all voids at low pressure to reduce possibility of cracks.
Industrial basement to be filled, but fill under basement is old rubble of limited load capacity.	Sand or flowable fill could be used here, but limited load capacity of existing floor may allow later settling and cracking of floor to be poured on new fill. Cellular concrete of 30 to 40 pcf will provide plenty of strength for new floor, but minimize load on existing basement floor.
Abandoned cistern needs to be filled before new driveway poured.	Constructed of limestone, the cistern is partially filled with debris and dirt with only a small opening. Excavation and fill with sand could be done, but would delay project and have potential for later settling. Cellular concrete in 30 pcf range can be easily placed to fill cistern through existing 16 inch opening.
Precast utility building of full density concrete is heavy and expensive.	Cellular concrete in the 100 to 110 pcf range reduces both the weight and cost while maintaining good strength.
Excavation around older basement wall threatens wall if back-filled with conventional fill materials.	Cellular concrete in the 40 to 50 pcf range places minimal lateral load on wall during placement and after cured provides both waterproofing and thermal insulation.
Designer wants cast in place bathtub/shower in existing structure with minimal structural modification for increased weight.	Cellular concrete in the 70 to 80 pcf range is solid and within acceptable weight range. Bonus is reduced cost. Note: PEX tubing installed in floor and sidewalls for heating of tub.
Owner wants soundproofing and fire resistance of concrete interior walls, but structure was not designed for full density concrete weight.	Cast on sight cellular concrete walls in 65 to 75 pcf range easily placed in position and within acceptable weight limits. Bonus: Cellular concrete easily cut, grooved and accepts screws and nails for fast interior finishing.
Homeowner wants concrete tennis court base at lowered price.	Cellular concrete base in the 90 to 100 pcf range reduces cost to acceptable level. Bonus: Reduces freeze/thaw cracking.
Building footing depth to be reduced to less than frost depth by excavation. Remediation would be expensive.	Cellular concrete in the 25 to 30 pcf range provides R-value in range of 1.5 per inch and insulates the footing without expensive further excavation and reconstruction.
Utility trench and excavation will require extensive fill compaction to prevent post construction settling. Compaction threatens to damage newly installed lines if not fully supported.	Cellular concrete in the 30 to 40 pcf range provides adequate strength, flows around, supports, and protects utility lines. Bonus: Easily excavated or removed if required at a later date, all at a reasonable cost.
Homeowner wants new paver brick patio over old non-level patio.	Cap of cellular concrete provides level surface for uniform thickness sand base for new pavers. In a similar situation a limestone patio surface was constructed by embedding limestone directly in cellular concrete in the 60 pcf range which effectively provided grout, leveling and anchoring of limestone.
Landscape designer wants large planters and other pieces with lower weight and cost.	Cellular concrete achieves both goals.
Architect wants to use full ICF walls for exterior of house, but cost is beyond budget.	Cellular concrete reduces cost while maintaining sufficient strength with only minimal increase in reinforcing. Bonus: Cellular concrete makes positive increase in insulation of wall.
Architect wants to reduce steel structure costs wherever possible in commercial four story building.	Cellular concrete floor decks in range of 60 to 70 pcf over steel sub-deck provide all the advantages of full density concrete while greatly reducing steel structure required.
Retaining wall to be built over abandoned industrial dump site with complex slopes and annual flood threats, may require considerable excavation to reach solid base.	Retaining wall to be built over abandoned industrial dump site with complex slopes and annual flood threats, may require considerable excavation to reach solid base.
Homeowner wants permanence and look of concrete porch deck at "reasonable" cost.	Cellular concrete in the 70 to 80 pcf range saves cost and weight with minimal structural work.
Architect for livestock show arena wants permanence and low maintenance of concrete non-structural walls at minimal cost to meet budget.	Architect for livestock show arena wants permanence and low maintenance of concrete non-structural walls at minimal cost to meet budget.