Owing to their special qualities, expanded clay concrete wall panels are quickly becoming a preferred option in contemporary architecture. Because of their strength, resilience, and superior insulation, these panels are a desirable choice for both homeowners and builders. However, what are expanded clay concrete wall panels exactly, and why do people in the construction industry hold them in such high regard?
Expanded clay, a lightweight aggregate that offers excellent thermal and acoustic insulation, is the main component of these panels. Expanded clay is combined with cement and water to make a sturdy concrete that adds improved insulation and lighter weight without sacrificing strength. This reduces labor costs and construction time by making the panels easier to handle and install.
The environmental friendliness of expanded clay concrete wall panels is one of their best qualities. In order to create expanded clay, natural clay must be heated to a high temperature, which causes it to expand and create tiny air pockets. This produces a material that is more sustainable and energy-efficient in addition to enhancing the panels’ insulating qualities.
These panels also have outstanding soundproofing and fire resistance qualities. Expanded clay concrete’s natural qualities make it a great fire and noise barrier, giving any building an additional degree of security and comfort. Expanded clay concrete wall panels offer a dependable and adaptable option for both commercial and residential construction.
- What it is?
- Regulatory requirements
- Scope of application
- Wall design
- Varieties
- Specifications
- Calculation of the required amount of material
- Technology of building a house from expanded clay concrete
- Advantages and disadvantages
- Average price in Russia
- Video on the topic
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What it is?
The typical features of expanded clay concrete panels are their rough surface, rectangular shape, and grayish color. The slabs are lighter than reinforced concrete ones, but they look a lot alike from the outside.
The following are the standard sizes for block panel design:
- length – 30-720 (cm);
- height – 30-810 (cm).
Slabs of expanded clay concrete are frequently made to order based on specific dimensions.
The items are made of lightweight concrete and are regarded as environmentally friendly because of their makeup, which includes:
- cement of a certain brand (M50-M150);
- expanded clay or quartz sifted sand;
- burnt carbon granular clay;
- running water;
- additives that improve adhesive properties (for example, bitumen emulsion, aluminum powder, lime, gypsum, etc.d.).
The constituent parts are mixed, foamed, and compacted before the mixture is poured into molds to create the panels without the need for an autoclave.
Concrete can be obtained in the following forms:
- structural;
- thermal insulation and structural;
- thermal insulation varieties.
The former are utilized to build partition walls (internal walls) and the latter load-bearing walls.
The expanded clay block wall structure’s low weight and even load distribution around the building’s perimeter are its key characteristics. wherein compared to products made of reinforced concrete, the load on the foundation is 30% lower.
You can construct walls for basements, attics, garages, and any type of residential or commercial building using expanded clay concrete panels. The tongue-and-groove locking mechanism joins the slabs to one another.
The design of an expanded clay concrete panel has one to three layers:
- one continuous layer of composition (the most common type of slab) is intended for a continuous structural wall or additional thermal insulation;
- 2 layers are represented by the outer (load-bearing) and inner (thermal insulating) parts, and are suitable for thermal insulation and structural walls;
- 3 layers may include: an outer reinforced concrete layer, insulation and expanded clay concrete (depending on the purpose of the wall, it can be applied to both external walls and partitions). Three-layer – this is when a layer of glass wool, foam plastic or foam glass is added to a two-layer slab.
The panel’s internal longitudinal and transverse reinforcement gives the material its maximum strength. The wall product has a thickness of 400–600 (mm).
The majority of the time, expanded clay concrete panel products are installed from the inside, right behind the structural layer, and are utilized as insulation in cold climates.
Regulatory requirements
GOSTs outline the fundamental specifications for expanded clay concrete panels.
- 32488-2013 (external panels);
- 12504-2015(internal products);
- 25820-2014;
Additionally, a number of other documents contain standards:
- GOST 4.212 – requirements for the quality of manufactured concrete products used in construction;
- GOST 6133 – technical conditions for the use of artificial stones;
- GOST 10181 – testing of concrete mixtures;
- GOST 12730.0 – general requirements for all concrete;
- GOST 30459 – additives for concrete;
- GOST 32496 – aggregates for lightweight concrete, etc.d.
Additionally, follow these guidelines when building any expanded clay concrete product:
- GOST 32488-2013 – on external walls;
- SNiP 23-02-2003 – on thermal protection;
- STO 501-52-01-2007 – on the design of concrete structures;
- STO-NO "SPKiK" – 001-2015 – about buildings made of expanded clay concrete.
Panel material has many beneficial properties that can be categorized into three groups: dense, porous, and large-porous depending on how they are structured.
The fundamental guidelines of GOST 28984-2011 govern all panel sizes based on their intended use.
Scope of application
Because they have low thermal conductivity, are adaptable to all types of landscapes and climates, and can sustain a comfortable temperature inside buildings for extended periods of time, expanded clay concrete panels are used in construction.
Slabs are used in their construction:
- residential buildings with a small number of floors (1-2);
- indoor ceilings;
- various outbuildings;
- insulating layer of walls inside and outside houses;
- soundproof partitions;
- fences and posts;
- foundations for log houses.
Because of their natural ventilation system and light weight, the constructed buildings won’t require forklifts to be placed because of their low foundation load. Slabs of expanded clay concrete are categorized as non-flammable, resistant to harsh chemicals, and having significantly higher density, strength, and frost resistance than products made of other lightweight concrete.
Wall design
A panel wall is made up of the specific number of layers required to form the entire structure.
The standard for wall pie is:
- structural (load-bearing wall);
- a layer of waterproofing on both sides of the main wall – outside and inside (layer of bitumen);
- suitable insulation (for example, polyurethane foam, mineral wool) on both sides of the panel;
- ventilation gap between layers (at least 40-50 mm);
- facing or decorative external materials (brick, plastic, tiles, any types of natural stone, etc.d.);
- interior finishing (plastering, puttying or installing drywall).
Since expanded clay concrete is thought to be porous and permeable, the general guideline for wall panel arrangement is double waterproofing, such as using roofing felt. Such defense will increase the longevity of any building structure and shield the walls from changes in the atmosphere.
Builders advise utilizing insulation and multilayer slabs (two or three layers), such as a mix of layers of heavy concrete and expanded clay concrete, when building walls in cold climates.
A monolith will shield the structure from the exterior, and a microclimate will be produced by the expanded clay concrete. The temperature will be sustained by the insulating layer. In this instance, internal waterproofing will be sufficient.
Expanded clay concrete wall panels are a great option for contemporary building projects because of their exceptional thermal insulation, lightweight strength, and soundproofing. Expanded clay aggregate, cement, and water are combined to create a material that is easy to work with and long-lasting for these panels. By preserving constant interior temperatures, their porous structure not only lowers the overall weight of buildings but also improves energy efficiency. Expanded clay concrete panels are also eco-friendly since they use natural materials and contribute to reducing building energy consumption.
Varieties
Expanded clay concrete panels are classified into groups based on their purpose, design, and whether or not layers are present, in compliance with GOST 11024-84.
As a result, the following categories are included in the product classification:
- By design (appearance characterizing all types of walls):
- solid (solid);
- prefabricated (assembled from several blocks).
- By function, depending on the type of construction:
- load-bearing (structural);
- self-supporting (partition, interior);
- hinged (thermal insulating).
- By number of layers:
- with low porosity (for rooms in which there is no heating);
- with certain proportions (according to the number of components of the mixture, which determines their purpose);
- layered (pie design according to specified design parameters, can contain up to three layers).
- By cutting method:
- vertical;
- horizontal;
- privates;
- corner.
- According to layer production technology:
- with adhesive composition;
- with solution;
- with welding.
Panels designed to fit a particular kind of wall are highly valued. For instance, structural products are thought to be the most well-liked. They carry out a crucial role in load bearing, guaranteeing load distribution around the building’s perimeter as it is being built.
Because structural slabs need to be highly load-bearing, the most durable concrete grades are used to make them. The layers that enable the panels to be used (select the type) define their unique properties, which are contingent upon the climate of the area in which the building is to be erected.
The inner layer of the slabs is reinforced with wire or special steel. Certain panel models might have hinges that facilitate easy stacking and interlocking.
Specifications
Expanded clay concrete panels are a warm, eco-friendly material that is allergy-free and safe for human health. They are known for their porosity and good air exchange, which enable you to build a "breathable" layer of the wall even when using extra layers and waterproofing.
Thanks to the mineral makeup of the incoming materials and a carefully selected cement brand, the panels resist mold growth and atmospheric degradation. They also have excellent sound and noise insulation qualities. The fact that the material is far less expensive than pricey monolithic is another significant feature.
The technical attributes of expanded clay concrete panels encompass several distinct indicators, such as:
- Strength (in general, for all varieties) – 150-1000 kg/m2.
- Frost resistance – 50-200 cycles.
- Moisture resistance – 50%.
- Thermal conductivity – 0.15-0.45 W/m2.
- Density – 500-1800 kg/m3.
- Wall shrinkage after construction – 0%.
- Average weight of 1 slab 2510-3950 (kg).
- Weight of 1 m2 of wall – 500-900 kg.
- Length – 2980-5980 mm.
- Width – 1180-1780 mm.
Class B, which is defined for expanded clay concrete products based on GOST standards and the cement grades utilized in manufacturing (M 300-500), is responsible for determining their quality. The pie structure will be denser and stronger the higher the M index.
Alphanumeric values are used to mark products; some indications may be rounded. For instance, 2НСΝ 40.27.thirty is the designation for external panels with two layers.
The walls don’t shrink, but they still need to be built on a solid foundation. After all earthworks are arranged and completed, a slab monolithic foundation or a strip foundation with a medium depth is used, and it is allowed to shrink for six months to a year. They then start to build walls after applying 1-2 layers of waterproofing to the established foundation.
Using reinforcement and bandaging, structural wall panels are installed in a checkerboard pattern. Don’t forget to create lintels, or ceilings, for window and door openings. Additionally, a reinforced belt is placed beneath the building’s roof or the second story.
Calculation of the required amount of material
It is advisable to let experts handle the accurate calculations for the project that is currently being built. They will carry out all tasks in compliance with the project plan and technological maps, applying the appropriate formulas and accounting for all relevant subtleties.
When doing the math, consider:
- area of the house, taking into account floors and the presence of a pediment;
- slab dimensions (length, width, thickness);
- safety factor (1.1)
The front area of a single wall is calculated by multiplying its length and width, and the total area of all the walls is then found. Windows and door openings are counted independently.
In this instance, the computation formula might resemble this:
- A – the required number of panels;
- IN – the total area of all wall surfaces;
- WITH – indicator of the area of 1 panel;
- 1.1 – safety factor.
Multiplying the product’s quantity by the average market price yields the required amount of funds. The total number of panel products is found by adding the area of the structural walls to the partition walls’ found area, which is added in accordance with the building’s given dimensions if partition walls are present.
To obtain precise and expert panel calculations, get in touch with experts at a nearby architectural firm or building company that handles product manufacturing and installation.
Technology of building a house from expanded clay concrete
Every kind of construction project always starts with preparation, which includes:
- drawing up a project (the entire scheme and types of future work) and approving it at the local architecture bureau;
- selection of a foundation in accordance with regulatory requirements for soils (landscape, groundwater occurrence, nearby communications);
- performing earthworks (marking the territory, clearing and removing the fertile layer, digging and constructing a pit for the foundation);
- backfilling of sinuses;
- establishing the time for shrinkage of the foundation (tape – 6 months, monolithic – 1 year);
- purchasing the necessary consumables and checking them for quality (presence of markings and declared characteristics from the manufacturer);
- agreeing on the work plan and estimate with the selected construction company;
- creating a waterproofing layer on the foundation after its shrinkage;
- pouring and screeding a monolithic floor for a strip foundation (not necessary for monolithic slabs).
Significant Expanded clay concrete slabs have the unique quality of covering the walls with waterproofing for finishing on both the interior and exterior. This eliminates vapor barrier and water absorption flaws and prolongs the life of the wall that has been installed. Cold bridges can be eliminated during installation by packing jute insulation into the slab joints. Welding, cement mortar, and glue are used in installation work.
Using a protractor and a tensioned construction cord, the first row of slabs is laid starting at the designated corner (column) on a bed of premium cement-sand mortar (M500). Tenon joints will be used to join the slabs to one another.
Mounting fasteners, also known as anchor devices, are used in the construction of internal walls. Products are always layered with one layer on top of the foundation and another layer underneath it.
Additional reinforced rods with a 10 mm diameter are used to strengthen the floor slabs, forming reinforced belts beneath the roof and second floor as well as lintels. If preferred, monolithic panels can be installed in place of the expanded clay concrete panels in the designated locations.
The wall pie should have a thickness of 400–600 mm.
The following is the technology used to lay expanded clay concrete slabs:
- Monolithic or brick corner pillars-columns are installed along the perimeter of the building at a given floor height. Monolithic ones are made to order in advance, and brick ones are made during the construction stages. The slabs will be connected from the pillars, using mortar and sealing the seams with construction adhesive, vapor barrier, foam or bitumen mastic, as well as welding the slabs together.
- Concrete (or glue) is poured into the space between the products and jute tape is laid. In order for the first panel from the corner to be well secured to the column, you need to drill a hole at an angle and hammer in reinforcement from 12 mm.
- Process the second panel connected through the tenon joint by welding along the reinforcement laid on top. Attach other panels in the same way. Remove excess parts by cutting with a grinder and a diamond wheel. Connect the panels in the corners with each other using anchors (60-80 cm long, 20 mm in diameter).
- Do not forget to secure the first layer of slabs to the foundation, but remember that the top slab is always attached to the underlying one. The slab is easier to lay with a lifting device, but if it is small in size and light in weight, then a couple of builders can handle it.
- It is best to lay the slabs on top of each other in a checkerboard pattern, cutting off the dimensions with a special tool. You can order semi-block slabs from manufacturers. At the same time, using halves of slabs, it is worth making calculations or preparing (cutting) the material in such a way that there is no waste of unnecessary parts.
- The surface of the slab is tapped with a rubber mallet, the remaining mortar is removed. Be sure to check the evenness of the masonry and the compliance of the panels with the key joints.
- A reinforced belt is made by using reinforcement rods and filling floor slabs with cement mortar. You can pour both expanded clay concrete products and monolithic ones.
- After 2 days, the walls outside and inside are wrapped with rolled waterproofing, applying it vertically or horizontally, or combining both installation methods. The rolls are attached to the wall with mastic (cold or warm). Rolls dry within 24 hours and completely harden in up to 7 days.
- The installation of partition walls (internal walls) begins 1-7 days after the structural. Here, the installation of panels occurs according to the load-bearing type – the first layer is on cement mortar and attached with anchors to the foundation, the second – to the bottom. But here you will also need an anchor to the main wall. Seam sealing is also required.
- After the work has been completed, you can begin finishing and cladding. Expanded clay concrete panels can be finished with decorative stone, brick, plastic.
When using mortars for sealing and masonry, the seam thickness shouldn’t be more than 12 mm. Using a wall chaser, it is simple to insert the rods into the holes.
Although expanded clay concrete is thought to be a reasonably warm material, it is still a good idea to add more thermal insulation in regions with harsh winters. The future owner requests that insulation be installed. Mineral wool slabs or polystyrene foam are the best insulators for expanded clay concrete slabs. On a dry wall that has been treated with a special glue, insulation is applied starting at the corners.
Dowels hold the heat insulator blocks in place as they are pressed up against the wall. It has a mesh installed on top of it, which is followed by the pouring of plaster and finishing. Remembering to include ventilation is crucial when insulating a wall (20–30 mm).
If mineral wool is utilized, aluminum foil can be placed on top of it or specifically designed double-sided insulating slabs that have already been foiled by the manufacturer can be bought.
During the panel-laying process, all regulatory guidelines are closely followed. Forming openings in accordance with the design drawing is required. The work uses a variety of fastening materials, such as channels and extremely large angles.
Advantages and disadvantages
The following are some benefits of expanded clay material:
- Environmentally friendly material (completely natural base of constituent elements) + prevents the formation of fungi, moss and mold.
- Non-flammability (belongs to the “NG” group, cannot ignite on its own).
- Good thermal conductivity (provided by the lightness and porosity of the structure, which are created by the reactions of additives of polymers and expanded clay – an important granular clay substance).
- Compactness and lightness (1 slab, depending on the size, replaces 1-2 m2 of brick, the material is lighter than a monolith, so it is easy to work with – quick installation).
- Frost resistance (react normally to low temperatures).
- No shrinkage + do not put load on the foundation.
- The price is several times cheaper than monolithic slabs.
- Durability and strength (provided by the composition and internal reinforcement used).
- High level of protection from external sounds and noise.
- Maintaining a comfortable indoor microclimate and a “breathable” wall layer + high vapor permeability.
- No reaction to UV rays and chemical elements + not afraid of corrosion.
- Easily processed and finished + well compatible with any building materials.
Disadvantages of slabs
- The need for waterproofing from the outside and outside, as well as sealing internal seams.
- Requires exterior finishing.
- Not suitable for foundation construction.
Because of the material’s many more benefits than drawbacks, using it is thought to be a wise choice.
Average price in Russia
Expanded clay concrete panels are thought to be less expensive than monolithic ones, as was previously mentioned. The cost of the materials included in the composition is included in the price, which accounts for the materials’ brand and quantity, the production method, the distance from the site (for individual production orders), delivery to the designated address, the number of panels, the urgency of the work, and the purpose of the project.
In the Russian Federation, the average cost of various kinds of slabs is (roughly) per piece:
- 500 x 620 x 90 mm (standard) – 550-750 rubles.;
- 6000 x 1200 x 250 mm (large) – 4700-6800 rubles.;
- 6000 x 1800 x 250 mm (the largest) – 7,000-8,600 rubles.
Thermal insulation panels cost half as much as structural models, which are the most expensive. The region of manufacture has an impact on panel prices. In the Russian Federation, St. Petersburg, Moscow, and Novosibirsk are regarded as the most costly cities. The panels are more expensive the larger their dimensions.
For one builder, the cost of building expanded clay concrete walls is about 1,480 rubles per day (8 hours of labor). Since the work is done quickly, the urgency of the procedure also has an impact on the cost.
Half the price is what contract workers charge for their services. However, since guarantees cannot be demanded from hired workers, if professionals work under a contract with a guarantee from a construction company in the first instance, then in the second, issues and mistakes might surface that will need to be fixed in the future.
Characteristic | Description |
Material Composition | Expanded clay, cement, and water |
Thermal Insulation | Good insulation properties, keeping homes warm in winter and cool in summer |
Weight | Lightweight compared to traditional concrete |
Strength | High compressive strength, suitable for load-bearing walls |
Sound Insulation | Effective in reducing noise transmission |
Fire Resistance | Non-combustible, providing good fire protection |
Durability | Long-lasting and resistant to weathering and chemicals |
Environmental Impact | Eco-friendly, made from natural and recycled materials |
For contemporary architecture, expanded clay concrete wall panels are a cost-effective and adaptable option. They are perfect for both residential and commercial buildings because of their remarkable insulating qualities and lightweight design. These panels improve thermal performance and sound insulation by adding expanded clay aggregates, which helps create a cozy interior atmosphere.
An additional important aspect of expanded clay concrete wall panels is their durability. Over time, they lower maintenance costs and ensure longevity by fending off fire, moisture, and pests. They are an affordable option for both builders and homeowners because of how quickly the construction process can be expedited by their simplicity of installation.
Expanded clay concrete wall panels are appealing due in large part to their environmental benefits. Sustainable building techniques are supported by the use of natural clay aggregates and the possibility of recycling these panels at the end of their useful lives. They therefore complement green building initiatives and are an environmentally friendly choice.
All things considered, expanded clay concrete wall panels provide a useful and environmentally friendly substitute for conventional building materials. For a variety of construction projects, their strength, insulation, and environmental advantages make them an excellent option. Building codes are constantly changing, and these panels are a novel approach that satisfies the needs of contemporary building.