AAC(Aerated Autoclave Concrete) using Aluminium powder

How do I make aerated concrete using aluminium powder?

I want to make lightweight concrete for a cover for my campervan. It's +100 degrees Fahrenheit day after day and I  live in the van.   But it's too hot.  

The idea is to make concrete beams using

Light steel frame (aluminium profiles) forms filled with aerated concrete to make beams.

Size of 4 aluminium forms to make longitudinal beams
3 meters long x
0.05 meter thick   x
0.20 meter deep

Filled above with aerated concrete

Then I will make roof panels.

I used a formula from Pioneer-group.com as a guide and this was my ratio guide:

1 part Portland cement ~ 500g
1 part NHL5 hydraulic lime (don't know lime %) ~ 500g
0.65 millilitres water
Mix above well into a slurry add
1 gram Aluminium powder

Results
First batch was too runny and nothing happened not much reaction
Also the volume was insufficient for the form so a complete mess up

Second batch
This was too dry as I increased the dry mix and didn't properly adjust water ratio
Wow this heated up and when I added the aluminium powder it had the mini explosion effect in the drum and so the mix couldn't pour

Used a deep drum which seemed to add heat from hand mixer and nhl5 and I was scared the drum would melt or it would explode.

Third batch
6 kilograms Portland cement
6 kilograms NHL5
8 litres water
Mixed well in smaller drum (to reduce heat build up)
12 gram aluminium powder

Still not a satisfactory reaction and I've ended up with a beam that is heavy.  Circa 20kgs heavy.  Might seem obvious because that's the weight of raw material but because it's not rising I compensated and filled more of the form.

I was expecting to use 1 cubic meter of mix to get 3 cubic meters taking into account the aerationration effect. This is not happening.

My thoughts are
Ground water I am using may be too acid and I should ensure neutralised by adding bicarbonate of soda before adding to make slurry
That NHL5 does not have enough limestone in mix.  Proper Limestone in Portugal needs to be ordered by the pallet which I am not about to do until I at least know I can make DIY aerated concrete.

Any tips on making aerated concrete with aluminium powder?

PS. In the meantime, I've got double 80% shade cloth on the van.  I'm using a swamp cooler.  Keeping my feet in cold water.  Ice facecloth. Really would like help on mix and building with aerated concrete because I'll then use this on the roof of my tiny house.  

I'll also experiment with latex in cement to make thin shell structures later on.

sorry no experience of using this method, helped out a friend do the aerated concrete stuff --needs a compressor though of decent volume out put ---but from this and my own preferred h/crete use for my project. The dry mixing first of the various ingredients then adding in water helped us on the small batches of stuff we were mixing  , but that means 2 mixers ,as one has to be kept dry and tipped into the wet mixer for each batch.

tony uljee wrote:sorry no experience of using this method, helped out a friend do the aerated concrete stuff --needs a compressor though of decent volume out put ---but from this and my own preferred h/crete use for my project. The dry mixing first of the various ingredients then adding in water helped us on the small batches of stuff we were mixing  , but that means 2 mixers ,as one has to be kept dry and tipped into the wet mixer for each batch.

Next experiment will be aircrete with foam and we have an air compressor. I've noticed it is often mentioned the importance of mixing mix well.

I'm also keen to try flying concrete for the roof.

my own interest in lightweight mixes was for the making of  panels ,for a raised bed and the best info i have seen so far is from a site ---man about tools---  , he has done various experiments and all recent stuff  ,but i have since had a re think about light weight panels though might be too fragile for the project i am planning ,hope it helps , the weather heat problem sounds trying---could it get worse in the future ?, maybe a start for going underground totally or even partially with a root cellar type build and earth roof.

forgot this, the nhl5 lime is a hydraulic setting lime ,so it is lime but with added pozzlans and has been manufactured /processed to accelerate its setting time, which the added in portland cement would have a similar  effect on  ordinary lime as well , the ordinary lime is hydrated lime ,which is made from purified lime and water putty mixed  and then has been dried and milled to a powder. Sorry for sounding like an expert knowitall, just have a friend who has worked all his life as a stonemason on historic conservation sites mostly--i get corrected or guidance from him on my projects