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Aircrete PLUS shredded plastic?

This topic contains 5 replies, has 4 voices, and was last updated by  Dave 2 years ago.

Steven R Denault steveca4

Aircrete PLUS shredded plastic?

08/05/2018 at 18:20

I’ve been looking into Foamcrete / Aircrete. Basically add foam to concrete and create lots of air bubbles, reducing the weight of concrete blocks, panels or other building components.

Why not also add shredded plastics instead of sand.

Foamcrete floats. One member mentioned the need for floating homes in flood areas. This foamcrete and plastic waste might work and it will use up recycled plastics?

The machines should be made to utilize whatever energy is locally available to reduce the need for electricity. For instance, dog, donkey, horse powered shredders? Or even bicycle drive. I’m not an engineer but there must be a way to gear the equipment so that the above kinds of power could be used to operated the plastic shredder.



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16/05/2018 at 04:32

Keep up the research. Presently working on using plastic strands to replace the existing Fiber glass strands used in concrete for reinforcement.  These strands are 3/4 to 1 inch in length, the thickness of a piece of paper and 1/16 inch wide.  The present cost of glass fiber is 10.00 a pound.  One needs between 1 1/2 to 3 pounds per cubic yard.   Imagine all of the tonnage we could eliminate by adding this to our concrete.
Yes, shredded plastic does work as a substitute for sand and gravel plus gives the concrete elasticity.
Plastic rebar that does not rust and is as strong in the concrete.  Every small plastic manufacture could sell locally to building contractors.

16/05/2018 at 05:59

@loadbuster. I like your ideas of using plastic instead of glass. Do you need some one to make these sizes for you?  I would definitely be interested. It sounds like your time would be best spent on the “brick” side.

16/05/2018 at 15:37

That would be great if you could experiment with this filament.  Viewed a you tube video “Homemade Plastic Extruder for Making Growing Media” check this out. If you could make a roll of this with the tiny grooves and perforations that would allow the concrete to bond to it better than a smooth surface.  Another idea I got was watching the other video “Plastic (HDPE) shredding for ”  if one could use this type of shredder to cut the strands width and somehow feed the flat film into it so that it shreds.   The width does not have to be precise but not wider than a 1/16th of an inch.
Every community uses concrete to build something, everything and every crack in the sidewalks could have been avoided if some form of reinforcement would have been used.  Fiber strand reinforcement only makes concrete better. Don’t plan on using for brick but rather concrete log siding that looks like rustic logs.
The siding is rodent proof, moisture resistant, mold and mildew resistant and does not burn.
It is going to take some testing for tensel  strength but I imagine tons of plastic being able to be used in every community across the world to be used to help reinforce their concrete and adobe mixes.  Check out concrete reinforcement as well to see how it improves the strength.
We plan on using a Spacecrete mix with fiber for insulation combining with recycled Stryrofoam that anyone can produce with a simple grinder.
Another item that is needed in quantity is re-bar tees; these are used to hold the  rebar to a desired height as the concrete is poured around them.  The need for items for the building trade are endless.   Keep researching!

16/05/2018 at 19:50

So aircrete with plastic long fibers might be better than ground plastics.
Wonder if a good office shredder would turn plastic milk jugs into long shreds.
Then mix those long shreds into a mix of concrete cement, fly ash and generated foam (like shaving foam made from dish soap). One could also include finely chopped Styrofoam add even more insulation value.

The cement would still need to dominate the mixture but talk about a great way to reduce building costs, add insulation and use up a lot of waste products. The blocks or building pads this could make would be far lighter to handle.

Now all we need is a uniquely shaped block or panel that would build a complete structure/home with just one shape. Perhaps a mold for a geodesic dome panel that does the whole building including the roof. Strong, insulated, dome shaped: the perfect building.

10/07/2018 at 17:53

Shredded and sized Styrofoam is a game changer in aircrete.  You can make it lighter stronger and more water resistant.  Enstyro designs and sells equipment to make outstanding concrete aggregate from recycled EPS.  A simple grinder crushes the foam too much and doesn’t give the right size range.

The importance of aggregate size and surface is well known in concrete.  Those properties are even more important when your aggregate is nearly weightless and water resistant.  Check out http://www.enstyro.com if you want to bring the next generation of foam recycling to your region.

Floating concrete is simple when you have the right mix of EPS aggregate sizes. Similar to sand and gravel in normal concrete, but with  near weightless, moisture resistant aggregates.

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