Lightweight Concrete, Foamed Concrete, Lightweight Ceramics, Landfill Cover, Firefighting Foam

GENERAL DESCRIPTION

An Allied brochure on Foamed Concrete is Available for Downloading in .pdf Form -

May, 2014

1. Allied Foam Tech has been awarded by USCA as the best chemical machinery & equipment manufacturer in Montgomeryville, Pennsylvania in 2009-2011, 2013 & April, 2014.

2. May, 2014- Our innovation (click here for details) on "Wood-like Flexible Cementitious Foam" received silver medal of the 2014 Edison Awards and we are joining the rank of winners like Apple, 3M, Boeing, and other current and past winners. Edison Awards will promote Allied's innovation to a wide variety of business press and media outlets.


Allied Foam Products & Foam Machinery have been used successfully for many years by clients in making cement backerboards & building blocks (click here for more Detials)
(The foam cement backer boards shown below (w. ISO Certificate by client) did not incorporate Allied new flexible foam cement technology)
Packed 8' x 4' x 1/2" Foam Cement Backer boards	Building A with Foam Cement Backer Boards	Building B with Foam Cement Backer Boards	Building C with Foam Cement Backer Boards	Building D with Foam Cement Backer Boards

HUMIDITY RESISTANT FOAM GYPSUM CEILING TILES

Moisture & Humidity Resistant Foam Gypsum Ceilings by Client Using Allied Licensable Cross-linking Foam Technology

1.5-1.7 lbs./ft² at 1/2" thick with acoustic & fire resistance properties

FLEXIBLE CEMENT PANELS, FLEXIBLE CEMENT SHINGLES & FLEXIBLE CEMENT BOARDS
TECH LICENSE OPPORTUNITIES (January, 2014)
Allied Foam Tech, through its ~ 20 years of internal R & D effort and global industrial experience in building trade, has developed a wide range of proprietary lightweight building composites, process and performance properties based on its patent pending lightweight fiber cement technologies and composites. Major building product manufacturers interested in licensing rights please click here.
A few highlights are given below:
· 1. Superlight and flexible cement sheets with great adhesion characteristics, high water resistance, and high impact and compressive strengths (MOR > 750 psi, indented compressive strength > 1,000 psi and 24 inches static water column test > 48 hours). · 2. Lightweight and flexible (roll forming) decorative sheetings for various exterior or interior wall wrap or wall covering applications. · 3. Asphalt-free flexible shingle (110-130 mils) and underlayment materials (50 to 70 mils) with UV resistance, freeze-thaw stablility, great coating and granule adhesion, tear strength and lightweight that is not available in the current roofing industry. · 4. Foamed curable thin sheets, with their uv stability, flexibility, high tensile strength, great adhesion to metal and water resistance, are very adaptable for the manufacture of roofing shakes and metal roof tile composites. · 5. Lightweight flexible cementitious coatings for the various commercial foam boards such as polystyrene and polyurethane foam boards. · 6. Lightweight cast stones with high mouldability (low slump), good fire resistance and quick demolding behavior, high tensile strength and adhesion for pigment and coloring should be very suitable for direct replacement of the various heavy stone or other concrete cast stone products. · 7. The flexible cementitious composites allows prefabricated or cast in place sandwich panels of various kinds to be made. Extrudable cementitous composites can also be engineered allowing for friendly adaptation of the various manufacturing process, curing and storage capabilities.

A TRULY FLEXIBLE CEMENT BACKER BOARD MADE WITH ALLLIED TECHNOLOGY (click here for more details)
A 1/2" CEMENT BACKER BOARD AT THE WEIGHT OF A 1/2" GYPSUM BOARD
high modulus of rupture (> 750 psi), high indented compressive strength (> 1,000 psi) with the highest water barrier properties in its category
1/4" Allied Flex Backer w. Nail	1/4" Hardie Backer w. Nail		1/4" Durock Backer w. Nail


ALLIED FLEXIBLE CEMENT BOARD	ALLIED WOOD LIKE FOAM CEMENT(d=41pcf)	ALLIED WOOD LIKE FOAM CEMENT(35 pcf & 1/16" thick)	ALLIED WOOD LIKE FOAM CEMENT (d = 41pcf)
MOR > 750 psi (density = 45 pcf)	clean cut w. wood cutting saw	trimming with a pair of scissors	excellent screw holding capacity	hole boring without chipping

ACOUSTIC CEMENT PANELS, WATER PERMEABLE FOAMED CEMENT & FOAMED CONCRETE

Click here for QuickTime Nov., 2014

The world's first foam cement and concrete with control of % Open POREs vs Close POREs

* economical porous material for all weather acoustic panels *

* WATER PERMEABLE FOAM CEMENT AND FOAM CONCRETE *

(acoustic panels for highway, mine, tunnel, railroad, mass transit, power plant, subway, marine vessel, airport, heat pump)

Mostly Open Pores

Mostly Closed Pores

Click here for QuickTime Nov., 2014

Such foam cement can easily reach a compressive strength of > 270 psi at an air dried density of 29 pcf.

*All the commercial pervious lightweight cement systems rely their permeability on either the very coarse open pores or the interconnected capillaries derived from severe foam collapse. Such cellular cement composites are typically very low in compressive strength, e.g. 80 - 150 psi at densities ~ 30 pcf.

Foam concrete or lightweight concrete derived from Allied's aqueous foams are suitable for both precast and cast-in-place applications. Some of the highly insulative cementitious foams at densities 48 kg/m³(3 pcf) to 645 kg/m³(40 pcf) or higher can be used as block fills, lightweight roof deck and void-fill materials. Good strength characteristics with reduced weight make lightweight concrete based on Allied's aqueous foams suitable for structural and semi-structural applications such as lightweight partitions, wall and floor panels, and lightweight blocks. Cementitious foams derived from Allied's premium systems are suitable for thin layer coating applications where specific performance criteria are required.

Foamed concrete and foamed cement made with Allied's foam have very fine pore structure, unlike that made with conventional proteinaceous and surfactant foams. The pore structure of Allied's foams hardly show any sign of deterioration as the density of the foamed cement decreases to below 160 kg/m³ (10 pcf). At densities below 160 kg/m³, the pore texture of foamed cement derived from conventional foam agents becomes so coarse that most of them show severe structural collapse.

The dynamic nature of Allied foam systems allows different foam rheology to be incorporated into the host cement/concrete matrix to satisfy a wide range of slump loss requirements.

The inert nature of Allied foam systems makes them compatible with different kinds of aggregates, fillers, extenders, retarders, accelerators, colorants, hydraulic inorganics and many other additives.

Allied foamED insulative cement WITH "0" SLUMP AND LOW DENSITY (< 5 pcf)

Allied Low Slump CEMENT Geofoam/GEOTECHNICAL FILL - A GAME CHANGER in the Geofoam MarkET
Allied "Cement Geofoam" will greatly simplify the application and cost relative to the "Expanded Polystyrene Geofoam"
Highway Embankment, Bridge Underfill, Landscape Architecture, Slope Stabilization, Levees, Airport Runway, Road Construction
Allied 5-15 pcf Fiber Low Slump Cement Geofoam	Conventional 0.7 - 2 pcf EPS Geofoam
	>
>>	>
Low load on the surrounding soil	Low load on the surrounding soil
Casting with a continuous low slump pour	stacking of individual blocks delivered on site
Shape & conform to the landscape easily with the low slump cast	Shape & conform to the landscape easily with the precast blocks
Foam formation onsite through compressed air and foam agent	Huge number of eps blocks have to be delivered on site
No fire hazard, good solvent resistance	Fire hazard, lack of solvent resistance(membrane needed)
Intimate soil contact with easy surface leveling and slope build-up	Sand leveling or other means needed for block alignment
Uniform and bulk cast without gap formation or concerns for buoyancy, individual piece heaving/floatation	Geomembrane or separation layer needed to avoid uneven block floatation or dissolution by organic liquid seepage.
Uniform & continuous pour/cast with ease of contour buildup	Interblock locking plates may be needed for block alignment
Wide range of density and strength possible:5 - 50 pcf, 2 >500psi	Density and strength are limited - 0.6 - 2.0 pcf, 2-10 psi.
For more details click here.

Allied Low Slump Cementitous Geofoam - easy to shape & conform to the landscape without moulds
Cast w/o Mould - Wet	Cast w/o Mould - Dry (d=25 pcf)	Mould-free Cast- Wet	Mould-free Cast - Dry (d=8 pcf)

Fiber Re-enforced Allied Cement Geofoam vs EPS Geofoam - Very Comparable Toughness During Compression

* Higher compressive strength can easily be reached by a slight density increase of Allied Cement Geofoam, e.g. 85 psi at a density of 16 pcf.

November, 2013

GEOPOLYMER FOAM

Density = 2.9 pcf (47 kg/m³), R Value = 3.84 ft^2oFh/(Btu in)

Highlights on Allied’s WORK with Foamed DECORATIVE STONES, Blocks and Foamed Panels

(WE PROVIDE FOAM PRODUCTS, FOAM MACHINERY AND TECH SERVICE IN PROCESS & MIX DESIGNS)

Autoclaved aerated concrete (AAC) was introduced in Europe over half a century ago as a lightweight construction material. The key features AAC has over conventional foamed concrete are significantly better strength and lower shrinkage/cracking. However, most of the attempts over the last few decades to introduce AAC to the US either failed or hardly made any signifcant impact to the construction industry. The million of dollars of capital investment needed for the manufacture of AAC over the conventional precast plant is just one of the many reasons reported in the literature.

Freshly prepared decorative stone panels with low shrinkage and non-cracking features are shown below:

3.6 feet x 2.6 feet (1.1 meters x 0.8 meters)

Total weight = 28 pounds or 12.7 kg.

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(the blue center block was acid-etched showing the blue decorative sand texture underneath)

Dimensions of individual panel = 22" x 8" w. thickness of 0.25"-1.25" (0.56meter x 0.2meter w. thickness of 1.6cm-3.2cm)

(weight per panel = 3.5 pounds (1.6 kg.)

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Extrudable Foam Cement Blocks

Freshly prepared cement/aggregate bricks/blocks derived from Allied's specialty foams with high slump loss may even be extrudable and thus amenable for mass production. A freshly cast foam brick at 37 pcf (600 kg/m3) without using any mould is shown below:

Freshly Made Foam Cement Brick w. High Slump Loss (density = 37 pcf)	Extruded Foam Cement/Ltwt Aggregate Composite (density = 40 pcf, compressive strength = 660 psi (4.6 MPa))	Instantly Demolded Cement/Ltwt Aggregate Composite (density = 31 pcf, compressive strength = 460 psi (3.2 MPa))
(a mould-free cast)	(low pressure extrusion)	(demolded in < 1 minute)

Highlights on Allied’s WORK witH Geotechnical engineering, LANDSCAPE ARCHITECTURE AND SLOPED ROOF DECK

Composites with Allied’s premium foamed cement/high slump-loss/high strength 35 pcf foamed cement allows greater and simpler landscape architecture and roof deck designs not achievable by any conventional cellular concrete.

1. Geotechnical Engineering & Landscape architecture

A. conventional cellular concrete - conventional 35 pcf LDCC (Low Density Cellular Concrete) with shaved expanded polystyrene blocks.

Very limited slope negotiation for conventional cellular concrete – less than ½ inch drop per 10 feet span.

Geofoam/styrofoam blocks of various sizes/shapes are needed to create artificial slopes.

Labor intensive and slow process.

B. New and flexible designs with Allied’s high slump-loss foamed cement ^ back to top

Highly sloped landscape with > 1 feet drop per 10 feet span can easily be achieved.

The use of Geofoam/styrofoam blocks is significantly reduced or totally eliminated.

Labor savings and faster process.

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High Slump Loss Foamed Cement/Lightweight Aggregate Composites with Low Shrinkage at a Dry Density of 35-50 pcf (565 - 806 kg/m3)


> 2.5 feet drop per 10 feet span (1V/4H)	Full Size Air Conditioner Pad From High Slump Loss/Low Shrinkage Foamed Cement Composite
(dry density = 35 pcf)	(dry density = 48 pcf)

2. Improved Foamed Cement Roof Deck Designs

Highly sloped industrial and residential roofdecks or roofings become possible with Allied's high slump-loss foamed cement product and mix design.

Allied's stable foam with high slump loss can be applied directly on corrugated metal sheets of new or repaired roofs without foam dewatering and possible water leakage to the interior structure of the floors underneath while such problems have always been associated with conventional cellular concrete roof decks.

Using Allied’s 35pcf/10 pcf foamed cement composite as roof deck structure will achieve the right combination of thermal insulation and light weight like conventional cellular concrete/styrofoam blocks but with appreciable labor and time savings and the flexibility in roof deck designs with varied shapes and contours not achievable before.

Comparison of Roof Deck Composites from Allied's Foamed Cement Composite & Conventional Foamed Cement/Expanded Polystyrene Board Composite.

28 DAYS STRENGTH PROFILE AT 55 - 80 PCF (890 - 1,290 Kg/M³) - loadbearing and semi-structural.

(The following data are derived from mix designs that may have different slump loss characteristics from that at 30 - 60 pcf)

Density (Air Dry)		Compressive Strength
(pcf)	(Kg/M³)	(psi)	(MPa)
56	900	1,200	8.2
65	1,040	1,480	10.2
69	1,110	1,700	11.7
74	1,190	2,300	15.9
76	1,240	> 2,500	> 17.2

COMPOSITE BLOCKS, PANELS - non-loadbearing, low-load bearing & insulative.

Even at densities < 20 pcf, the strength development of Allied's foam/lightweight aggregate composites allows <24 hours demolding time while still maintaining good handling characteristics (all three blocks shown below were demolded in 18-24 hours and were immediately saw-cut to proper size)

Panels and Blocks Based on Allied Foam & Lightweight Aggregate Mixes

36 pcf - 46 pcf	Cross Seection of Foam/Aggregate Panel

Foam/Aggregate Blocks 35-45 pcf (565 - 726 Kg/M3)


Fiber Re-enforced Foam Cement Panels (50 pcf)	Held in Air - 1.5 inch thick

PERFORMANCE

Some Performance Features of Concrete and Cement Incorporating Allied's Foam Systems:

Consistent and fine pore texture at different densities

Low water uptake

Hight early and 28 day compressive strengths

Good thermal and acoustic properties

Wide range of rheological, adhesive and thin-set properties

24 HOURS STRENGTH DEVELOPMENT OF AFT FOAMED CEMENT IN VARIOUS MIXES

The excellent stability of Allied's foam products is demonstrated in the following pictures of lightweight cement and concrete:

Foamed Cement Using Allied AFT-400 Density = 0.24 g/cc (15 pcf)	Foamed Cement Using Proteinaceous Foam Density = 0.24 g/cc (15 pcf)

fine pores	coarse pores

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		Foamed Cement Cylinder	Foamed Cement Cylinder
Foamed Concrete (density=75 pcf)	Foamed Concrete (density=75 pcf)	(density=30 pcf) Allied AFT-400	(density=30 pcf) Proteinaceous Foam
		(high early strength cement formulation)	(high early strength cement formulation)
Allied AFT-300	Proteinaceous Foam	no foam collapse	severe foam collapse
uniform & fine texture	non-uniform & coarse texture			collapsed foam

Strength Development and Water Uptake of Foamed Cement

Allied foams are compatible with different kinds of cement, fly ash, sand/aggregate fillers, retarders, accelerators and water reducers. The AFT-400 series of foam reagents provide cement and concrete with very low water uptake. Cementitious foams at densities as low as one tenth (1/10) that of dense concrete will still maintain lower than 15% (by volume) water uptake in a 24 hour water immersion test.

The following table shows some typical strength and water uptake characteristics of a lightweight cement formulation using Allied AFT-400:

**FOAMED CEMENT FORMULATION WITH AFT-400** **- Strength** **Development and Water Uptake**
Density of Foamed Cement (in gram/cm³)	Compressive Strength		24 hour Water Uptake
	After 24 Hours	After 28 Days	(volume/volume)
0.74 (oven dried)	468 psi	825 psi	< 5 %
	(3.25 Mpa)	(5.3 Mpa)

(WE PROVIDE FOAM PRODUCTS, FOAM MACHINERY AND TECH SERVICE IN PROCESS & MIX DESIGNS)

APPLICATIONS

lightweight Architectural Precast

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Lightweight Concrete Roofdeck

click for larger view click for larger view click for larger view

slope building

low water uptake

controlled hydration

high early and final strength

Roofdeck Composite - Top View

Roofdeck Composite - Cross-Section

Foamed Lightweight Concrete Roofdeck

Lightweight Concrete Partition

tilt-up or vertical cast (save labor, time and

space)

thermal and acoustic properties

high early and final strengths

Partition - On site casting

Foamed concrete Partition

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Cinder Block Inserts

fire resistance

high thermal

insulation

efficient production

with consistent

quality

Cinder blocks filled with cement foam at density < 10 pcf

Block filling process

Filled Cinder blocks on racks before curing

On site block fill

Lightweight Blocks

click for larger view click for larger view

good thermal and acoustic properties

low water uptake

easy to work with using common tools

Foamed Blocks-Precast

Foamed Panels - Precast

Lightweight Wall and Floor Panels

click for larger view click for larger view

good thermal and acoustic properties

load bearing and lightweight

easy to work with using common tools

Wall Panel - Precast

Wall & Floor Panels

Hit Counter

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FOAM STABILITY AFTER PREPARATION - Allied foam vs. protein & surfactant based foams
O Hour			2 Hours			4 Hours			24 Hours

Surfactant Foam	Allied Foam	Protein Foam	Surfactant Foam	Allied Foam	Protein Foam	Surfactant Foam	Allied Foam	Protein Foam	Surfactant Foam	Allied Foam	Protein Foam


Mixing & Pumping of High	Applying of High Slump Loss	Finished Foamed Cement Crown	Cross-section of
Slump Loss Foam Cement	Foam Cement on 1 Vertical/4 Horizontal Slope	On Highly Sloped Geofoam	Landscape after ~ 1 year

HIGHLIGHT
Another example of low load pavement is shown by a recently renovated sports field on the roof of an existing gymnasium-120,000 square foot coverage with foamed cement pumped 3 stories high and 500 feet across the field. (the weight limit, compressive, shear and other performance demand and its intended use made the project one of its kind in the US roof deck industry.)
GEORGETOWN UNIVERSITY - Roof Deck for Sports Utility

Foam Sytem - AFT-450 series at 35 pcf (565 kg/m³)
Roof condition before	Roof preparation	Material Setup (20 ton cement bulker)	Equipment Setup (1 cubic Yard per Batch)

Pouring foam cement on the roof	Foam cement roofdeck	Turf application on the roof	Gym under the roof deck

FIRE HAZARD & TOXIC FUME RELEASE OF CONVENTIONAL FOAM INSULATIONS

Las Vegas, 2008	France, 2012	Dubai, 2012
Welder triggered PU foam fire	Foam insulation accelerated fire	Foam/metal panel accelerated fire