CAL Block & Panel - Cellular Concrete Technologies

lifegunbarrelcityUrban and Civil

Nov 26, 2013 (4 years and 7 months ago)


CAL Block & Panel

Panel ™

Lightweight, energy
efficient concrete blocks

CAL Block & Panel

Our Foaming Agent is a

specifically formulated to be environmentally friendly

The strength of the bubble is achieved in part because of its size and
structural characteristics.

Equally important to the structural strength of the concrete
is the adjustment to conventional raw material ingredients in terms of type, quality and

Through a standardized ‘Mixing and Handling Protocol’, batch plant operators will
know how to modify their usage of cement, water, sand, rock and other additives in order
to achieve the required compressive strength under a variety of climatic conditions and
operating parameters.

Stable Air's primary products have characteristics that make them superior
to other structural and non
structural concrete,
whether the concrete mix relies
on conventional, cellular or lightweight aggregate mix designs.

Stable Air structural,
lightweight cellular concrete is for use in load
bearing applications where 3,000 lbs./
or greater strength is required.

Stable Air lightweight cellular concrete is for use in

fill, non
structural and low
structural applications, where strengths under
3,000 lbs./ are sufficient.

CAL Block & Panel

Our Products Produce Excellent Results in ASTM
Tests for Industry Requirements

Stable Air products have produced excellent results in ASTM tests for
industry requirements
with ongoing tests taking place, and already meets product
requirements for selected uses at a lower cost. Stable Air products also significantly
improve the workability and

of the concrete, as well as greatly reduce the
deficiencies in sand.

While Stable Air products compare favorably to traditional dense weight concrete and other
cellular and lightweight concretes in many ways, they offer several additional

Cost to produce Stable Air concrete is usually about the same as traditional
concrete and less than other cellular and lightweight concretes (CLC).

Architects and
engineers can design lighter structures that are less costly to build
because building
components, such as steel rebar and other structural components are less costly when the
building structure is lighter in weight.

Structural costs are reduced where strength is not

Transportation and lifting cost are reduced for lighter
weight precast products.
Bleeding during placement and finishing is significantly reduced.

CAL Block & Panel


Roof Tiles

Wall Panels

Engineered Buildings


CAL Block & Panel

Block Production and Use

A typical block production plant

CAL Block & Panel

Curing Room


Ready for Shipping


CAL Block & Panel

CLC and Brick Comparison

Size 4 x 8 x 24 CLC Block market price now in India is 3500Rs./

Red bricks market price now in India is 2600 Rs./
. and varies
from city to city

CLC size

. (61,024 = m/3)

4 x 8 x 24

83 CLC


7.1 brick/CLC

589.3 red brick

6 x 8 x 24

55 CLC blocks

10.6 brick/CLC

583 red brick

9 x 8 x 24

50 CLC blocks



CAL Block & Panel


1 unit wall (100sf) brick construction with CLC and red brick:

Price Cement Rs 300/50KG bag

Price Sand 100/bag

CLC bricks per 1 unit wall construction (#75 Rs 45/ea.)

Red bricks for 1 unit wall construction (#560 Rs 4/ea.)

CLC Unit

Red Brick Unit


CLC Plastering ½”

Plastering Red Brick 1 ½”

Cement : 1 bag

: 1.5 bags

:2.5 bags



Sand : 4 bags

: 6 bags



:14 bags

Total: 400

Total: 1,000

Total: 600

Total: 1,400

Total Cost of CLC Brick, Mortar and Plastering RS 3375 + 400 + 1000 = 4775

Total Cost Red Brick, Mortar and Plastering RS 2240 + 600 + 1400 = 4240

Add labor mixing cement, labor transfer mortar and plastering and water

Add labor cost for installing 75 CLC Block to 560 Red Brick

(substantial savings on labor and construction time)

CAL Block & Panel








Thinner walls

Dry Density


800 (approx)


Dry Weight









Compressive Strength


25 @ 28 days.

with age

Adequate strength

Thermal Conductivity



Good thermal insulation

Properties Overview

Larger size

Thinner walls

Light weight

CAL Block & Panel

Why Use CLC Bricks?

CLC is a lightweight brick where water absorption is less compared to
redbrick and fly
ash brick

High thermal insulation


Reduced cement quantity consumption

Longer life
span compared to other bricks

CLC block size can be manufactured according to project requirements

CAL Block & Panel

min. Compressive strength of 3N/mm2

Bending strength is 15
20% of compressive strength

Reduces dead load on structures with a density of 800kg/m2

resistant and non
toxic fumes, in case of fire

Excellent earthquake resistance properties

Easy handling as lightweight CLC is easy to transport and stock.
Can nail
and cut chases for services easily compared to hollow blocks and
concrete blocks. This technology is being used worldwide

Highest thermal insulation for cool summers and warm winters

CLC Material Advantages

CAL Block & Panel

Excellent acoustic barrier. No disturbances from your neighbor’s home

Flexibility with wall finishes (external plastering, tilting, cladding, internal
tilting, dry lining, spray plaster or anything of your choice)

Reduced cement mortar and plastering from the accuracy of block
dimensions and decrease in the number of joints

Decreased width of CBW increases carpet area when compared to brick

CWB is available all year round and through all seasons, even during
monsoons when the availability of fire clay bricks is not consistent

CLC Material Advantages (

CAL Block & Panel

Considerably Lower Weight:
Weight reduction is obvious in transport, where almost
double the volume of building material can be produced. It has an impact on craning,
where either larger panels can be taken, or the full capacity in span. Alternatively, less
location of the crane is necessary.

Thermal insulation:
Thermal insulation increasingly turns out to e the most important
issue in the planning and construction of buildings. There are many costly ways of
insulation on sandwich structures of a wall, adding the one or another rigid insulation
material with a satisfactory result by computation, but not always a sound solution in
safety, health or environment. The best solution is to incorporate thermal insulation in the
concrete mix, as offered in air
cured CLC.

Fire Protection:
The air
embedded in the CLC is also instrumental for the high fire
rating. In 1200 kg/m3 density, a 13
14 cm. thick wall has a fire endurance of 5 hrs. The
same delay occurs with a 400 kg/m3 layer of CLC in only 10 cm. thickness. CLC is
otherwise non

Insulated Flooring:

As the impact force will not transmit, slabs produced of CLC or
topped with a layer of CLC floor screen will prevent any sound heard in rooms below.
Walls of CLC will also serve as sound retaining walls on roads or railway tracks therefore
absorbing the sound and preventing it from bouncing to the other side.

CLC Material Advantages

In Detail

CAL Block & Panel

Customizable Physical Properties:

Adding fibers to CLC is a further important
benefit, increasing bending stress substantially and most
of its
impact strength. The
three dimensional acting fiber (e.g. polypropylene) will further reduce shrinkage,
therefore reducing water absorption and increasing strength (up to 25%). This is
appreciated most when producing slender building components.

Sound Insulation:

With the efforts to keep increasing the thermal capacity of building
members, other aspects have been neglected such as sound insulation. Sound is
experienced as air
borne or foot
fall sound (impact). Air
borne is a rule of density and
therefore, CLC offers superior protection over very light concrete (ACC). In impact
sound, it is superior to conventional concrete. Hitting a wall with a hammer will let you
feel the full force on the other side, whilst the air embedded in CLC will not allow the
blow to pass through. At most, it will suffer a small dent and thereby prevent any
greater damage.

The closed cell structure of CBWC blocks reduces water absorption.

CLC Material Advantages

In Detail


CAL Block & Panel

Faster construction, as custom size requirements can be cut on site using basic
power tools

Remarkable labor savings with a labor reduction from faster construction

Remarkable foundation and structural savings up to 30% of beam costs

Reduced air conditioning expenses. Energy requirements can be 5x lower than
conventional structures

CLC Financial Advantages

CAL Block & Panel

Savings in Raw Materials:
The tremendous savings described when using CLC are
manifold, continuing with substantial savings in raw material (no gravel required), in dead
load of high
rise reduced by almost half. Considering that a substantial amount of steel is
necessary only to carry the weight of the structure, steel requirements might be reduced
by hundreds of tons for a high

Economical Production:

Using only fly ash, cement, water, and foam, the cost for one m³
of CLC in most cases is less even than for the equivalent volume of conventional concrete.
Adding all the described highly appreciated benefits (comprising CLC) to regular concrete,
if at all possible, the cost for such regular concrete would probably double but still not
reach the overall quality of CLC.


thermal insulation of blocks results in lower

electricity cost due to reduced
conditioning loads.

CLC Financial Advantages

In Detail