5.1 Lightweight Concrete
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Lightweight concrete for this project is to be known as Compolite. It is a mixture of cement, fine sand, water and a special foam, which once harden results in a strong, lightweight concrete containing millions of evenly distributed, consistently sized air bubbles. It differs from conventional concrete in that the use of coarse aggregates is eliminated.
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The density of Compolite is determined by the amount of foam added to the cement, sand and water mixture. Compolite's density ranges from 250 to 1800 kg/m3, as compare to 2400 kg/m3 for conventional concrete. Therefore, the weight of a structure built of Compolite will be reduced significantly. Compolite is water-resistant and possesses enhanced sound and thermal insulation properties.
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Compolite offers several distinct advantages such as the followings:
- Reduces the dead weight of a structure.
- Good workability.
- Can be manufactured to precise specifications of strength and densities.
- Provides enhanced heat and sound insulation.
- Can be nailed, planed, drilled and sawn.
- Can be applied with all traditional surface finishes - paint, tiles, carpets etc.
- Moisture and fire resistant.
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5.2 Savings in Material
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Reduction in dead weights contributes substantially to savings in reinforcing steels in load-bearing structural components such as foundations. The dimensions and therefore, the overall quantity of steel reinforcement in Compolite can be reduced by as much as 50%. Savings are also substantial in transportation, crane-and manhandling related activities as well as in raw materials, as no gravel is required to produce Compolite but only sand, cement, water and air, with the resulting mortar/paste subsequently embedded in the foam. Casting very slender walls of 50 mm thickness can optimize the amount of materials used.
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5.3 Savings in Manpower
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The high flow ability of Compolite makes vibration unnecessary, and thus requires no prescription of vibrating equipment/accessories. Only a few semi-skilled workers are needed to produce Compolite for casting / pouring of panels, blocks or even complete walls for houses. Steelworks, formworks, brick laying and cement renderings do not constitute major site activities for Compolite building system. Therefore the related workers are not required. Workers are only needed to set up cost saving and reusable formworks, and for removal of formworks for next erection and casting.
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5.4 Easy application
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No special skill is required in applying the system. It is fully adoptable or at least adaptable into existing concrete or prefabrication plants, adding only the Compolite. Foam Generator to produce and discharge foam of a precise dose into the mixer. Compolite may later be pumped using conventional concrete pumps. Due to the absence of gravel and the ball-bearing effect of the foam, Compolite possesses a high degree of flow ability. No vibration is thus required and Compolite completely fills all gaps and voids in the concrete or mould, fully embedding any hoses, tubes, frames for windows and doors.
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5.5 Enhanced productivity
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The rapid mixing and high fluidity of Compolite facilitates speedy casting of building elements. With the application of vertical molds to cast complete houses in place, omission of vibrating equipment results in the entire walls and ceiling/roof of a building being filled in one step. Openings (or the actual frames) for doors and windows. Ducting and conduits for sanitary and electrical services can be cast in place and firmly embedded in the foam concrete.
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5.6 Minimum Cost
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As conventional concrete and prefabrication plants may be used to produce Compolite, the only investment that would be necessary is in the inexpensive foam generator and the foaming agent, and the latter contributes to only about 10% of the overall cost of Compolite.
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5.7 Acoustic Thermal Insulation
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Compolite possesses enhanced impact and air-borne sound absorbing properties, which are suitable for partition walls, and flooring applications. Compolite with a density of 1200 kg/m3, for instance, can produce a thinner monolithic wall, which requires fewer raw materials. It possesses better insulation properties compared to that of conventional concrete.
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