Expanded clay concrete

The construction industry is seeing a rise in the use of expanded clay concrete because of its many advantages. This durable, lightweight material is a favorite of both homeowners and builders. However, what is expanded clay concrete exactly, and why is it turning into such a popular option?

Fundamentally, expanding clay aggregates are combined with cement and water to create expanded clay concrete. A lightweight aggregate is produced by the porous structure of expanded clay, which is created by heating clay to high temperatures. This particular composition improves the insulating qualities of the concrete while simultaneously lowering its overall weight.

Thermal insulation is one of expanded clay concrete’s key benefits. Because of its porous nature, it can trap air, keeping buildings cooler in the summer and warmer in the winter. This is also an environmentally friendly option because it can result in significant energy savings over time.

Expanded clay concrete is renowned for its strength and durability as well. It is more resilient to wear and tear and severe weather than many conventional building materials. This makes it a great option for a range of construction projects, including both residential and commercial structures.

Knowing the advantages of expanded clay concrete can help you make well-informed decisions for your projects, whether you’re a professional in the construction industry or a do-it-yourself enthusiast looking to build or renovate. It’s an excellent material for contemporary building needs because it’s adaptable and provides benefits for the environment as well as practicality.

Application of expanded clay concrete

Because of its excellent thermal insulation qualities, expanded clay concrete is used in construction. Thus, bathhouses, warm outbuildings, and production and storage facilities can all be built using expanded clay concrete. Additionally, it can be applied to lessen the weight on the foundation.

Expanded clay concrete floors are large, lightweight structures that are used to build reinforced floors or homes with heated floors.

The surface needs a finishing coat to keep moisture from seeping into the screed or ceiling in order to guarantee durability.

Uses for expanded clay concrete mortars include:

Table showing expanded clay concrete’s attributes in relation to alternative building materials

Characteristic	Expanded clay concrete	Aerated concrete	Foam concrete	Brick
Density	700 – 1500 kg/m3	400 – 800 kg/m3	300 -1200 kg/m3	1550 – 1900 kg/m3
Strength	35 – 100 kg/cm2	35 – 65 kg/cm2	2 – 50 kg/cm2	150 – 300 kg/cm2
Frost resistance	50 cycles	25 cycles	35 cycles	100 cycles
Water absorption	18%	45%	10-16%	10-16%
Thermal conductivity	0.19 – 0.4 W/m°C	0.09 – 0.14 W/m°C	0.08 – 0.32 W/m°C	0.45 – 0.5 W/m°C
Soundproofing	53 – 60 dB	50 – 53 dB	30 dB	34 dB
Shrinkage	0.2 – 0.4 mm/m	0.12 – 2 mm/m	0.5 mm/m2	0.5 mm/m2

Based on granule size, construction expanded clay concrete mixtures in grades M100–M300 are separated into three categories:

The proportions of the constituents, the aggregate size, and their quality all affect the expanded clay concrete’s strength and density. It is separated into four categories based on its functional purposes:

1. thermal insulation;
2. septal;
3. wall
4. facing.

Use a minimal quantity of sand or none at all for the first and second groups. Wall expanded clay concrete is distinguished by its high strength and high fine aggregate and cement content.

Keep in mind the standards that the manufacturer mentions when placing your concrete order. The following regulatory documents outline the specifications for expanded clay concrete: GOST 25820-2014 and the updated GOST 25820-2021, which will go into effect on September 1, 2022.

Brands of expanded clay concrete

Determining the operational properties and technical parameters of expanded clay concrete compositions is made convenient and straightforward by separating them based on grade. We can take the most popular brands of mixtures as examples.

This brand’s materials are frequently used in non-operating parts of buildings and structures (non-load-bearing structures) for heat and noise insulation. These components might be things like empty floors and room dividers.

M75

Appropriate for the same uses as M50, but with enhanced parameters, it can also be used to screed floors that already exist, broadening its range of use and increasing its versatility.

M100

The most widely used material for building enclosing structures and monolithic floors is this lightweight expanded clay concrete. This material is robust enough to be used in the construction of year-round low-rise residential structures.

Just like M100, expanded clay concrete M150 is widely used. It possesses more advanced technical features. can be used to cast small monolithic floors, stairs, and other building elements; it can also be used to create high-strength screeds.

M200

These combinations fall under the category of structural lightweight concrete, which is employed in the construction of monolithic load-bearing components for both residential and commercial structures. Large-scale walls and ceilings are also constructed using the M200 expanded clay concrete mixture.

M250-M350

These structural mixes are extremely strong and resistant to moisture and frost. Bore piles, grillages, and foundations are examples of monolithic load-bearing structures that can be made with them. Although this building material frequently has a very high density, manufacturers can obtain maximum strength parameters of up to B40 upon request.

Table of comparative features for expanded clay concrete by brand.

Brands of expanded clay concrete	Strength	Density	Frost resistance	Moisture resistance
M50	B3.5/4.5MPa	D700-1100	F15-75	W6
M75	B5/6.2 MPa	D800-1200	F35-75	W2
M100	B7.5/7.5-9.5 MPa	D900-1300	F50-100	W2-4
M150	B10-B12.5/12-15 MPa	D1000-1500	F75-100	W4-W6
M200	B12.5/19 MPa	D1600	F75-100	W6
M250-M350	B20-25	D2000	F100-200	W6

Composition

Like its blocks, expanded clay concrete is created by adding expanded clay granules to a mixture of cement, sand, and water.

Granules in varying sizes give the material its light weight and thermal insulation, and they can be used to make a variety of block designs.

1. Water for concrete should not contain any impurities, as they can negatively affect the hardening process of concrete.
2. To achieve high quality expanded clay concrete mixture, sand must be washed from unwanted impurities and components.
3. Blocks will be stronger if the cement grade is not less than M500.
4. The ratio of expanded clay to cement plays an important role when creating mortar. If there is more expanded clay in the solution, then the strength of the solution will be lower, but it will be warmer. If there is less expanded clay, the solution will be stronger, but less warm.
5. Expanded clay can be crushed (more durable) or solid (warmer).
6. Compacting the block using powerful vibrocompression machines increases its density. The higher the degree of compaction, the less likely it is to have pores, which in turn provides greater strength.
7. An important factor when choosing expanded clay blocks is the presence of voids. Solid expanded clay blocks have higher strength compared to hollow ones with the same dimensions. This is due to the fact that the mass concentration of concrete is higher.

One characteristic of expanded clay concrete mixtures is the filler’s rapid absorption of water (burnt clay, expanded clay). Therefore, it is advised to prepare small portions of the solution and lay them out at the same time in order to prevent drying out of the solution and guarantee its uniform distribution. Preparing the next batch should ideally coincide with laying out the previous one.

Constructed from cement, water, and expanded clay aggregates, expanded clay concrete is a lightweight, adaptable building material that yields sturdy, long-lasting structures. This cutting-edge material offers superior fire resistance, soundproofing, and thermal insulation, making it ideal for contemporary architecture. It’s a green option because it uses less energy and requires less additional insulation. Expanded clay concrete offers builders and homeowners alike a workable and sustainable solution, whether for commercial, industrial, or residential uses.

Expanded clay concrete proportions

If we already don’t know the composition of expanded clay concrete, then the necessary strength will determine the proportions. For expanded clay concrete screeds in homes and apartments, a high grade is not necessary. Strength between M100 and M150 is adequate. Only when the project demands it should a screed with greater strength be made. Use proportions (cement, sand, and expanded clay), such as M150: 1 / 3.5 / 5.7, to mix expanded clay concrete.

You can use auxiliary substances to enhance the characteristics. As an illustration:

• quartz sand increases elasticity;
• large-fraction expanded clay improves thermal insulation properties;
• adding expanded clay gravel makes the material more moisture-resistant and durable.

Pros

Inexpensive. Compared to bricks, aerated concrete, and ceramic blocks, expanded clay concrete blocks are less expensive. The only alternative that is less expensive than expanded clay blocks is dolomite block.

Because of their great strength, the blocks can be utilized to build load-bearing walls for buildings. They can be as high as three stories, with the option to have wooden ceilings.

The durability of expanded clay concrete blocks is similar to that of brick. Their service life can be extended to a century with appropriate finishing and external wall protection.

Composition that is friendly to the environment. It is made entirely of natural ingredients, including water, sand, cement, and expanded clay. No surfactants or other chemical additives that might be bad for the environment or people’s health are used.

The specific gravity of blocks is two to three times lower than that of bricks. This allows for a reduction in foundation costs without compromising the building’s stability.

Masonry ease of use. Because expanded clay has a volume seven times that of brick, building a wall with expanded clay concrete blocks takes a lot less time.

High resistance to external influences: the substance doesn’t ignite or promote combustion, and it is resistant to chemical and biological influences.

Blocks made of expanded clay concrete are not very heatconductive. They are located in the space between brick and other widely used building materials like gas and foam blocks.

Complements a broad range of finishing materials.

Feature	Description
What is Expanded Clay Concrete?	A lightweight concrete made with expanded clay aggregates.
Key Benefits	Good insulation, lightweight, durable, fire-resistant.
Common Uses	Walls, floors, roof insulation, lightweight structures.
Installation	Easy to handle and place due to its light weight.
Environmental Impact	Eco-friendly, made from natural clay, recyclable.
Cost	Generally more affordable than traditional concrete.

A practical and adaptable building material, expanded clay concrete has many advantages for construction projects. Because of its light weight, it is simple to handle and move, which lowers labor costs and expedites the construction process. It is lightweight without sacrificing strength, resulting in strong, long-lasting structures that are resistant to a range of environmental factors.

Excellent thermal insulation is one of expanded clay concrete’s most notable qualities. This implies that buildings made of this material will be able to keep a comfortable interior temperature more effectively, which could result in energy savings for both heating and cooling. Its ability to insulate sound also contributes to the creation of calmer, quieter living areas.

Its resistance to moisture, pests, and fire is an additional benefit. These characteristics make buildings safer and longer-lasting over time, requiring less upkeep and repairs. Because it’s composed of natural materials and emits less carbon dioxide than regular concrete, expanded clay concrete is also a green option.

To sum up, expanded clay concrete blends sustainability, economy, and usefulness. Whether used for business, residential, or industrial purposes, it provides a dependable answer that satisfies contemporary building requirements. It makes sense that expanded clay concrete is becoming a more and more popular option in the construction industry given all of its advantages.

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