Pouring Aircrete in to A wall

Aircrete (aerated concrete) has the potential to change the way that the people of the world insulate and build their homes. We have been using our Foam Mate tool since 2018 to build wall panels and create greater efficiency in high heat applications like rocket stoves.
Our current, most exciting project is our Light and Portable Aircrete Rocket Stove. We used this stove in our uninsulated off grid house this winter and this little stove kept us toasty without putting any smoke into the air around our house. It is so well insulated our dogs sleep touching the stove even though the batch box registers up to 2000 degrees Fahrenheit when full of coals and wood.
This stove can be manufactured by anyone with a pop-rivet tool and a bag of refractory mix concrete. Go check out our plans! We are so excited to share the book with you. If you want to join us for live streaming of Darwin doing a weekly walk-through of the book join our Patreon! / honeydocarpenter
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[@dave_ecclectic]

6:34 good thing you have your safety glasses on 😀

[@muddy-one]

You should be able to get by with a diaphragm pump. You can get a chinesium Ingersoll Rand knockoff double diaphragm 1 inch inlet 1 inch outlet, 35 GPM, air operated pump for about $300 right now.

[@HergerTheJoyous]

Hey kid! Long time no see. Like the wood saw dist idea. You should pre soak the saw dust before you add it. Might help reduce the aircrete collapsing...I know it helps with paper pulp.

[@implanterion]

Darwin, you are awesome! I love your aircrete projects & the R&D that you do for the projects & ideas you create. Keep creating, man!👍

[@tuxiesicecream321]

Build a PVC double acting pump and mount to the bottom of your barrel. Some plywood pulleys and a belt should allow you to convert a cheap drill to back and forth motion to drive it.Tee a recirc valve ( flue damper) to the top of the barrel. start the pump with this open and close it to pump aircrete. You don't need fancy check valves, build homebrew flap valves and a damper for the recirc line. A little heat and you can flatten out cut PVC pipe to build any parts you need. Thanks for all your hard work!

[@dirtpatcheaven]

Love it!

[@melinda5777]

Hey Darwin, that looks great!!! 🙏❤🇺🇸⛵👣🤗

[@yvehill]

Really miss your videos. Would love to know how the winter was for you and how building is coming along.

[@MultiVoiceofreason]

Get the pump built quickly

[@HansQuistorff]

I was contemplating fastening the foam mate to the side of the barrel feeding into the barrel. When the batch is ready clamp the lid on and turn on the air tot the foam mate and the pressure would push the aircrete out a gate valve and hose used fo waste tanks.

[@unoken1]

Liked Subscribed and Shared from Minnesnowtah 😊

[@jaredcolahan759]

love the vids, question , how do you connect the panels together, it looks like only sprayfoam ?

[@RobertXavier-kl8bj]

Saw dust is Organic Aircrete has both air & moisture Won't that cause the saw dust to rot away, releasing heat & gas and crack the aircrete?

[@backwoodsbungalow9674]

Good to see the first test batch of your latest aircrete recipe mixed and poured into a wall of your forever home. 👍 Have you figured out why the aircrete settled so dense and how to get a lower density? 🤔

[@bruceh4833]

It's an inventor's mistake that I would have made also. The aircrete bubbles just can't hold that much vertical column above 4 inches or so before the weight crushes the air out. They can be poured flat and tilted up, but the slump weight column height wins. That may be why some are turning to shredded packing foam like Aircrete Harry instead of soap foam for structure builds. Aircrete performs very well as an insulator for the rocket stove with thin walls and ratio of thickness between the sides of the refractory core and the outer sheet metal core holding it versus the height of the pour may be sufficient to keep the air entrained. Which means the rocket stove might cure aircrete a little better setting horizontally that vertically. The ratio of height of the pour to the thickness may just be thin enough in the rocket stove to keep the column from squishing out the soap bubble air with vertical pours. I'm no expert. DO TRY THIS AT HOME! Lol.

[@duanethieme4186]

Keep up the good work! How does it compare with basic aircrete (without sawdust) for insulation and settling? Thank you for all that you do aircrete, rocketstove, etc,.....!!

[@ECDDan]

Darwin, I've been missing alot of your videos lately but caught this one, great! I must have missed the video or place you posted trying out the mix with sawdust and your findings etc., can you direct me please.

[@crossbowmd61]

! Why did you create such a huge form, for just a 12-15" pour? Why not just use a 24" form and work your way up the wall in stages? This way, you could move right on to the next section, left or right, while the first one is setting up. It would not only have been easier to pour the first 3-4 vertical stages, (5-6'); but, also, you would not need to use such a large sheet of plastic, either. Just a thought. Great job, though.

[@michaelknight1617]

Any idea what the weight per sf of the aircrete is in the 6" cavity once cured? Also did the wood absorb any of the evaporating water and deform it? I have a stick built house that is gutted and thinking of trying it.

[@ValentineBernier-Wallace]

I'm just learning about aircrete so I have a question. Doesn't pouring this mix into a form, in a way, defeat the purpose of aircrete? This a a foam and compressed air product that if poured beyond a certain depth causes the air and foam to collapse which is why the end result of your pour seemed deficient to your expectations and in the end uses substantially more product than required. It would seem much more efficient to build a reusable jig out of Melamine and pour these flat then attach to your frame, additionally pouring in place seems extremely labor intensive compared to pouring flat and then attaching. I also noticed on your shed build that you kept the metal forms on after pouring which seemed unnecessary and costly. From what I have learned this product should be structurally sound enough on its own. Again, I am just learning and I am looking for some direction so please do not take this as a jab but rather a legit inquiry. Also, one more question, this concerning the 2x8 panels you poured for your shed. Why not pour 4x8 as most sheets of construction board is 4x8 standard. I appreciate you. Val