How to make a foam generator for foam concrete with your own hands?

Foam concrete is becoming more and more popular in construction as a cost-effective and adaptable building material. Its cost-effectiveness, superior insulation qualities, and lightweight design make it a desirable choice for a range of applications. But foam concrete can be pricey to buy, so a lot of do-it-yourselfers are considering making their own.

A foam generator is a necessary piece of equipment for making foam concrete. This machine creates the foam that is required to combine with water and cement to make the finished product. Commercial foam generators are available, but they can be expensive and impractical for personal or small-scale projects.

Fortunately, you can construct your own foam generator at home using some common materials and a little bit of creativity. By following this tutorial, you will be able to build a working foam generator and make foam concrete at a reasonable cost. You’ll learn how to improve the economy and efficiency of your construction projects by adhering to these instructions.

Option 1 – mini production of foam concrete with your own hands using ready-made equipment

To make foam blocks at home, one must buy an installation, which is a specific set of tools or machinery, and mix the foam concrete mixture on their own.

Composition of the foam concrete mixture:

• cement (Portland cement, grade M-400 and higher. The cement must be fresh) – 310 kg;

• sand (fine-grained or crushed, sifted sand) – 500 kg;

• water – 210 l;

• foaming composition – 1-2% by weight of cement;

• modifying additives.

Let us examine the foaming agent in more detail. You have two options: either make it yourself or use a ready-made composition, like PB-Lux (90 rubles/kg) or Foamcem (150 rubles/kg).

Do-it-yourself foaming agent for foam concrete

Foaming agent composition:

• caustic soda (caustic soda) – 0.15 kg;
• rosin – 1 kg;
• wood glue – 0.06 kg.

The manufacturing process requires a fair amount of time and labor. As such, it is recommended only for large amounts of work.

How to make a foaming agent for foam concrete at home

There are two phases to preparation:

1. mixing the adhesive solution. To do this, pieces of dry glue are filled with water (1:10) and left for a day. During this time, the glue will swell a little, but will hold its shape. Therefore, the container with water and glue is heated to 60 ° C (with constant stirring). The adhesive solution is ready when all the pieces have dissolved and formed a homogeneous mass;
2. making rosin soap. For this purpose, the sodium is brought to a boil. Then rosin is gradually introduced into it. The boiling process will take about 2 hours until the rosin is completely dissolved. Note. Rosin should be crushed first.

Once the rosin soap has cooled to 60 °C, the two compositions are combined.

Note: Rosin soap is added to the adhesive solution while mixing. 1:6 ratio of mixing.

High-density foam is produced by adding the resultant mixture to a foam generator. For use with cubes, foam with a density of 80 g/dm is thought to be ideal. Using foam that is less dense and more airy will cause the block to lose quality quickly.

Note: You can use a bucket to fill with foam to see how good it is. The foam ought to remain inside the bucket after it has been turned over.

Diagram of the production of foam blocks

Be aware that the initial foam concrete blocks typically come out lumpy, just like the first pancake. This is due to a few factors:

• the difficulty of dosing the constituent components in the solution;

• increased/decreased water content in the solution;

• increased content of foaming agent in the solution. Its consumption should not exceed 1.5 l. per 1 m/cube. Firstly, because the foaming agent is expensive. Secondly, because increasing it in the mixture increases the time for concrete to harden. Thirdly, because it will reduce the strength of the block.

• varying the kneading time;

• experimental determination of time for building strength in blocks;

• drying mode of finished (unmolded) blocks.

Regretfully, these kinds of experiments not only increase construction time but also cost more. Users attest, though, that they are entirely justified. Additionally, damaged foam blocks can be sold and utilized as backfill beneath floors, as well as used equipment for making foam concrete.

Note: It is preferable to create structural foam blocks (grade D-900 and higher) as experience has shown. Compared to thermal insulation, they have fewer pores and are simpler to manufacture for novices.

Option 2 – making equipment for foam concrete with your own hands

Let’s start by noting the equipment that is typically required for the traditional two-stage production method of making foam blocks.

A small-scale plant’s manufacturing apparatus for making foam concrete consists of the following:

1. a foam generator with a compressor for air supply;
2. a mixer (in private production, a conventional concrete mixer is used);
3. forms for foam blocks;
4. additional equipment: pressure gauge, pump.

The apparatus used in a typical foam concrete plant

Let’s look at how to create each of the equipment types listed at home using unconventional materials.

DIY foam generator for foam concrete

The most costly aspect of production is the acquisition of this module.

The goal is to create foam out of the foaming agent before adding it to the solution.

The design of the foam generator consists of three units:

1. feed module. A foaming agent solution is poured into it. Any container can perform this function;
2. conversion module. The quintessence of the installation is foam conversion;
3. dosing module. Provides the ability to supply foam to a solution of a given density (determined by the brand of foam block).

Diagram of a foam generator for the production of foam concrete

You’ll need metal pipes (two blanks), a pump, hoses, and valves to assemble a foam generator. and a welding apparatus as well. The specification that is included with the foam generator drawing shows more specific parts.

Assembling a foam generator for foam concrete (diagram-drawing)

Making a foam generator

The factory foam generator tube is unique in that its initially narrow channel eventually widens. By using this method, you can accelerate the emulsion’s flow through the tube. It will then be moving at its fastest possible speed at the output.

How to make a foam generator for foam concrete with your own hands?

You must create the primary foam cartridge and a turbulent mixing chamber in order to accomplish this.

Making a mixing chamber

Join two pipes with a welding joint to form a ready pipe. Additionally, it’s best to put one of them—through which air will be supplied—at the very end. And weld (at a 90° angle) the second one, which is meant to supply the foaming emulsion.

Two valves are installed on both the end and side inlet pipes:

• shut-off (allowing you to shut off the flow of foam concentrate);

• adjustable (allowing you to adjust the supply parameters, change the pressure, pressure, quantity, etc.P.).

Control valves are typically not used after the mixture supply parameters have been altered.

Note: The side pipe’s diameter ought to be fifteen to twenty percent greater than the end pipe’s diameter.

Making a foam cartridge

To the second pipe blank, a pipe is welded. Its purpose is to discharge the completed mixture. To slow down the rate at which mixture exits, it is a good idea to install a funnel-shaped device on the outlet pipe. The workpiece is fitted with a filter. Its objective is to create foam from emulsion. Ready-made filters are available for purchase.

However, metal brushes or meshes can serve the same purpose just as well for cleaning dishes.

However, only wire ones work; spiral ones are inappropriate. Over the whole length of the foam cartridge pipe, these meshes must be packed as firmly as possible. A mesh washer is installed inside a "Ruff" that is installed at the pipe’s outlet to stop mesh particles from flying out with the mixture.

Connection of mixing chamber and foam cartridge

The mixing chamber and the foam cartridge must then be connected. It goes without saying that this must be done in order to position the welded pipes at opposite ends. You need to install a Laval nozzle or a jet washer between them to ensure that the foam concrete mixture passes through the tube more quickly. The efficiency of the design will be reduced by 30–40% if a jet is used in place of the nozzle because the mixture will pass through it more slowly. It can be used as a temporary solution, though, and it is less expensive and simpler to install. The diagram indicates where the nozzle or jet should be installed.

Foam generator size ratio (depth and inlet diameter) for foam concrete

2. Connecting the compressor to the end pipe of the mixing chamber

It is safe to operate any compressor that produces pressure up to 6 atm. You can control the pressure by using a compressor equipped with a receiver, a pressure-reducing valve, and a pressure gauge.

3. Connecting the foam concentrate container to the side pipe of the mixing chamber

The foaming emulsion (foaming agent plus water) is supplied to the mixer by passing through the side pipe of a container that is placed on the floor and has a hose attached to it. The installation of a small pump—a common household "trickle"—will enable the foam generator to receive foaming agent more effectively. However, the supply can also be arranged according to gravity to save money.

Such an easy-to-make foaming agent for foam concrete will be far less expensive than one that is bought. Furthermore, the foam produced will be on par with foam produced by a factory generator.

Building a foam generator at home to make foam concrete is an easy, affordable project that can save a lot of money on building costs. Using easily accessible supplies and equipment, you can construct your own foam generator by following the step-by-step instructions provided in this article. You will learn how to put together and run a foam generator to create high-quality foam concrete for your projects, regardless of experience level with do-it-yourself projects.

Homemade equipment for the production of foam blocks

Putting together a foam generator at home to make foam concrete

A mold for pouring foam concrete is the second, and easily DIY, step in the process of making foam blocks.

Step	Description
1. Gather Materials	Collect a plastic container, air compressor, foam solution, and hoses.
2. Modify the Container	Drill holes for the hoses in the container lid.
3. Connect the Hoses	Attach one hose to the air compressor and the other to the foam solution.
4. Secure the Hoses	Seal the hose connections to prevent leaks.
5. Prepare the Foam Solution	Mix water and foam agent as per the instructions.
6. Test the Generator	Turn on the air compressor and adjust the settings until foam is produced.

Building your own foam generator for foam concrete is a worthwhile and economical endeavor. Building a working foam generator will enable you to create high-grade foam concrete for your building requirements with a few simple steps and easily accessible materials.

You can gain invaluable practical experience and save money by using this do-it-yourself method. Understanding the foam generator’s essential parts, including the air compressor, foam agent, and mixing chamber, is necessary for assembly. Every component is essential to guaranteeing that the foam is continuously generated and uniformly combined with the concrete.

You can have more control over your construction projects if you take the time to build your own foam generator. This enables you to test out various foam densities and maximize the performance of your foam concrete for a range of uses, such as lightweight concrete blocks and wall insulation.

All things considered, building a foam generator is a doable and useful project. It gives you the freedom to experiment and adapt your building techniques, which could result in better outcomes and cheaper costs. Accept the challenge and take pleasure in the advantages of having a flexible tool at your disposal.

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