Thanks for this link, Paul! Just sent me down a rabbit hole of research. Aircrete sure has advanced since I last looked at it 10 years ago. For cold climates the insulation value looks interesting
It looks to me like the biggest issues are consistency of the homemade pours, and also building taller blocks, and reinforcement. I saw some anecdotal stuff about the air holes meaning traditional rebar and wire mesh doesnt hold up well. I think it looks really interesting for pouring single cast structures, but I see people having difficulties with foam collapse at pour heights of about 1 ft.
The blocks would worry me, just due to lack of reinforcement and inevitably having mortar that is stronger than the blocks (always a poor idea). Plus the mortar might provide thermal bridging.
I'm giving serious consideration to aircrete. I'm thinking of doing panel coops and maybe a small cabin down the road. I want to mess with it a bit before doing anything big but I'd like to do a deck, some interlocking panels, and maybe a smallish water container for ducks.
I'm going to see how much collapse I get with a couple of different foam agents, but I think Catie has outlined the issues.
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-Le Livre du Colon, 1902
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If you do, please share? There are also some Sika products that may increase the strength and decrease the set time which could theoretically be helpful/worth trialing.
I was thinking if you could get a reasonable (1-2') pour height, especially if you could mix with a quick setting product that allows you to do multiple lifts per day, and reinforce with plastic mesh near the surfaces, a rectangular building with an arched roof should be reasonably easy to form and pour and reasonably strong.