Home > Plant
Casting Insulation System


Foamed Concrete Casting Insulation System


    Foamed concrete casting insulation system can be used for Omni-directional insulation that includes walls (steel structure & framing structure), roofing, and flooring.  It is non-toxic, no harm, fireproof, and its life is the same as the building. It is an ideal insulation material for construction.




Comparative advantages to foam plastic

A.     Problems with foam plastic materials

    Construction becomes a hot area because of governmental policies of energy saving.  In order to reach a 50% energy saving goal, Beijing and many other provinces adopted foam plastic insulation for outer walls, roof, and floor. Although it is effect, foam plastic reveals following 5 problems.

1.      Foam plastic is easy flaming, with massive toxic smoke.

2.      Foam plastic’s aging characteristic shortens insulation time.

    Foam plastic’s lifetime is 15-20 years, while a building has a lifetime of 50-100 years long. This means a building has to rework on insulation 2 to 5 times within its lifetime. Reinsulation increases cost, causes damage to the building, and its waste is harmful to the environment.

3.      Peeling exists when foam plastic and wall don’t form well. Foam plastic is an organic material, so it is hard to form with walls.

4.      Foam plastic intensifies resource crisis

5.      Foam plastic shrinkage causes many problems

    Because of long time pressure, foam plastic in roof and floor becomes thinner, therefore causes shrinkage to protective and decorative layer. Meanwhile, aging insulation causes cracks to decorative layer.

    From above information, it is clear that foam plastic disadvantages outweighs its advantages

casting steel structure wall

Casting wall

Workers are readying for fixing board

test foam concrete

foam concrete machine is working

Finished wall


B.     Advantages of foamed concrete casting insulation system:

1.      Construction and insulation can be finished at the same time.

2.      This system’s main material is cement, therefore, it is fireproof.

3.      Same lifetime with the building

4.      foamed concrete is an inorganic and environmental friendly material, and it is none toxic, tasteless, and pollution free

5.      no shrinkage or peeling that later triggers cracks after final finish

6.      No oil resource is needed, good for saving energy.



Foamed Concrete Casting Wall

Steel structure and concrete will be main framework, and frame with light steel keel. Put fiber cement templates (8-12mm) at both side of the keel to form a hollow of 100-150mm thick. Cast density of 300---400kg/m3 foamed concrete into the hollow, and casting insulated wall is formed after hardening. There is no need to remove fiber cement templates because it protects foamed concrete, reduces water absorption, and increases foamed concrete life due to high density wall surface. At the same time, it saves a mortar layer; and the walls can be paint and put decorative materials on directly.

Figure 1: Foamed concrete casting wall structure



Figure 2: Casting foamed concrete wall templates



    In general, foamed concrete casting wall’s thickness is 10-15 cm,  20-30 cm in cold area, density is 300-400kg/m3, thermal conductivity is 0.07-0.09w/m·k, (These data should be designed and calculated to be exact, however it does reach for 65% energy saving.)

    Foamed concrete casting wall is the main technology in the insulation area, it is our exclusive technology. After solving many technical problems, we proudly provide following technology.

1.      Foamed Concrete Hardening Problem in the Hollow

Because pumping is widely used in construction, foamed concrete casting wall generally use big water-cement ratio, otherwise it is too difficult to pump in remote distance. Water-cement ratio is 0.6 in construction, but there will be some water increases when add foam; therefore, the actual water-cement ratio shall be 0.7. Because lots of water in cement slurry, it is difficult for concrete to dry in closed hollow. In the research stage, we found that slurry didn’t dry even three days later. After repeated studies, we eventually solved this problem, and now it can dry within several hours.

2.      Casting Height

Lower level foam disappears when cast too high because too much pressure is loaded and foam has weak bearing ability; therefore causes collapse, or density difference, such as higher density in lower level. This technical problem has caused foamed concrete casting height remains at 10-20cm, and no one has reached 60 cm. However, we solved this problem by intensive study and reaches 1 meter casting height without layer, collapse, and density difference. It is a leading technology internationally.

3.      Foam Loss When Pumping

Since pumping pressure damages foam, there are massive foam losses. In general, the higher it pumps, the more foam it loses. As a result of this, there is a density difference between different floors. Our technology helps with minimize foam losses almost to zero.

Foamed Concrete in Flooring

Figure 3: Foamed Concrete Flooring

Structure from bottom to top:

1.      Floor or floor slab

2.      Insulation Layer: roughly 4cm foamed concrete

3.      Floor pipe: cross-linking polyethylene pipe (water-hot), heating Cable, and electric membrane. 40-60 ℃ hot -water pipe is the most popular.

4.      Thermal Conductivity Layer: fix floor pipe, transfer heat evenly and radiate heat, avoid partial high temperature.

5.      Floor Surface & moisture-proof material : such as wood flooring and tile, also laying floor leather

Three Innovations in Floor Insulation

1.      Mixing

    We use 30% - 60% fly ash, steel slag, mineral slag, and sand to mix with cement with a much lower cost; others mainly use cement (higher cost) although result in layers and collapse because lack of technology advances.

2.      Anti-cracking

    Most of our rivals face cracking when slurry hardens, to an extreme that the cracking is 1 meter long, 2mm wide. We minimize this problem, and improve the entire quality.

3.      Unique foaming agent formula

    Compare to our competitors, our foaming agent requires less input, dries faster, and not compressed. (0.7-1 kg for every square meter foamed concrete)

Foamed Concrete in Roofing

    Foamed concrete casting in roofing is widely used internationally, but only to flat roof; our casting technology works both on flat and sloped roof.

1.      Flat Roof

    So far, there are 2 ways of roof insulation, one is waterproof layer is below foamed concrete, and the other is above foamed concrete, but mostly below.

Ø      Blow Foamed Concrete (Figure 4)

    Advantages: 1) avoid waterproof pipes directly expose to the sun; 2) increase waterproof layer life and roof water resistance:

    Disadvantages: it needs a protection layer

Ø      Above Foamed Concrete (Figure 5)

    Foamed Concrete directly casts on troweling layer (leveling layer), and put a waterproof layer on top of foamed concrete.

    Advantage: it saves a protective layer, because waterproof layer can protect foamed concrete, Disadvantage: waterproof layer is not protected.


Figure 4


                                           Figure 5                                           


    Advantages in roofing: less joints, cast-in-site, massive construction capability. With the same material, same density, and some thickness, our foamed concrete casting insulation is 20% better than rivals’. Casting foamed concrete thermal resistance value is 5-10 time to heat insulation bricks.

2.      Sloped Roof

    We innovated casting in sloped roof successfully, see Figure 6 for details.


Figure 6: Sloped Roof Insulation


Foamed Concrete Casting Capacities:

Density 400~450kg/m3foamed Concrete techniques

                 Compressive Strength: 0.4~0.6MPa

                 Thermal Conductivity: 0.07~0.10 w/m·k

                 Water absorption     ≤25%

Casting Equipment

    Our FM-20 runs with material feeding, mixing and pumping in a sequence. See parameters below:



Delivery Height (m)

Delivery Distance (m)



Main Structure (mm)

Mixer Dimension


Material Feeder Dimension (mm)












Main Component

1.      32.5 or 42.5 grade Portland cement

2.      Fly ashes, steel and mineral slag mix with 30%-60% water

3.      Foaming agent: 0.7~1kg/m3

4.      CA-1 accelerator: this is a multi-functional agent; it shortens hardening time, and stabilizes foamed concrete. 1-2% input in general.

Cost in Chinese Yuan (400kg/m3)

Concrete                        231 kg x¥350/ton ≈ ¥80.85

Mixed Material (sand)       115 kg x ¥60/ton ≈ ¥9.20

Foaming Agent                    1 kg x ¥13/ton ≈ ¥13.00

Accelerator                         4.6 kg x¥4/ kg ≈ ¥18.40

Labor & miscellaneous                                ≈ ¥20.00

Other Material                                            ≈ ¥5.00

Total Cost                                                 ≈ ¥146.05