Lightweight concretes

Lightweight concretes can either be lightweight aggregate concrete, foamed concrete or autoclaved aerated concrete (AAC). Such lightweight concrete blocks are often used in house construction.

Lightweight aggregate concrete

Lightweight aggregate concrete can be produced using a variety of lightweight aggregates. Lightweight aggregates originate from either:

Natural materials, like volcanic pumice. The thermal treatment of natural raw materials like clay, slate or shale i.e. Leca. Manufacture from industrial by-products such as fly ash, i.e. Lytag. Processing of industrial by-products like FBA or slag.

The required properties of the lightweight concrete will have a bearing on the best type of lightweight aggregate to use. If little structural requirement, but high thermal insulation properties, are needed then a light, weak aggregate can be used. This will result in relatively low strength concrete. Lightweight aggregate concretes can, however, be used for structural applications, with strengths equivalent to normal weight concrete. The benefits of using lightweight aggregate concrete include:

Reduction in dead loads making savings in foundations and reinforcement. Improved thermal properties. Improved fire resistance. Savings in transporting and handling precast units on site. Reduction in formwork and propping.

Foamed concrete
Foamed concrete is a highly workable, low-density material which can incorporate up to 50 per cent entrained air. It is generally self-levelling, self-compacting and may be pumped. Foamed concrete is ideal for filling redundant voids such as disused fuel tanks, sewer systems, pipelines, and culverts - particularly where access is difficult. It is a recognised medium for the reinstatement of temporary road trenches. Good thermal insulation properties make foamed concrete also suitable for sub-screeds and filling under-floor voids.

Autoclaved aerated concrete (AAC)

AAC was first commercially produced in 1923 in Sweden. Since then, AAC construction systems such as masonry units, reinforced floor/roof and wall panels and lintels have been used on all continents and every climatic condition. AAC can also be sawn by hand, sculpted and penetrated by nails, screws and fixings.

Classification of Aggregates
The variability in density can be used to produce concrete of widely different unit weights, see Table (1). The most common classification of aggregates on the basis of bulk specific gravity is lightweight, normal-weight, and heavyweight aggregates. This section specifically address the different characteristics found in both lightweight and heavyweight aggregates.
Table (1), Density Classification of Concrete Aggregates, Mindess Category Unit Weight of Dry-rodded Aggregate (kg/m3) <500 500-800 650-1100 1100-1750 >2100 Typical Concrete Strengths (MPa) <7 7-14 17-35 20-40 20-40

Unit Weight of Concrete (kg/m3)

Typical Applications

Ultra lightweight Lightweight Structural Lightweight Normal weight

300-1100 1100-1600 1450-1900 2100-2550 2900-6100

Nonstructural insulating material Masonry units Structural Structural Radiation shielding

Heavyweight

Lightweight aggregates: As mentioned in the body of this paper, lightweight concrete contains aggregate that is natural or synthetic which weighs less than 1100 kg/m3. The lightweight is due to the cellular or high internal porous microstructure, which gives this type of aggregate a low bulk specific gravity. The most important aspect of lightweight aggregate is the porosity. They have high absorption values, which requires a modified approach to concrete proportioning. For instance, slump loss in lightweight concrete due to absorption can be an acute problem, which can be alleviated by prewetting (but not saturating) the aggregate before batching.

Lightweight aggregates are covered in ASTM C330 (for structural concrete), C331 (for masonry units), and C332 (for insulating concrete). Additionally, these specifications all contain the requirement that aggregates should be composed of predominately lightweight-cellular and granular inorganic material. Expanded clay, shale and slate are the most common materials found in lightweight aggregate used in structural concrete. Properties of concretes made with lightweight aggregate are listed in Table (2).
Table (2) Properties of concretes made with lightweight aggregate, Mindess Aggregate Aggregate Dry Unit Weight (kg/m3) 550-1050 Origina 28-Day Compressive Strength (MPa) 14-42 14-42 14-42 0.67-3 0.6-3.5 4-5 9 0.7-12.5 7.7-21 21-50

Concrete Unit Weight (kg/m3)

Absorption (Wt %)

Expanded shale, Clay, slate Foamed slag Sintered fly ash Exfoliated Vermiculite Expanded perlite Pumice

PN

650-900 600-1000 65-200 65-250 250-500 30-150 750 1450-1750

S S PN PN N S S S N

110-1850 110-1850 1350-1900 400-950 550-800 800-1300 1200 300-900 1750-1900 2250-2400

5-15 5-25 14-24 20-35 10-50 5-10 19-36 0.5-2.0

Expanded glass Expanded polystrene beads Brick rubble Crushed stoneb

a PN,

processed natural material; N, natural material; S, synthetic material b Natural aggregate listed for comparison

Heavyweight aggregates: Heavyweight concrete contains aggregates that are natural or synthetic which typically weigh more than 2,080 kg/m3 and can range up to 4,485 kg/m3. Heavy weight aggregate is most commonly used for radiation shielding, counterweights and other applications where a high

mass-to-volume ratio is desired. ASTM C637 covers aggregates used for radiation shielding and Table (3) contains the physical properties of heavy weight aggregates.
Table (3), Properties of heavy weight aggregates, Mindess Material Classificationa Bulk Specific Gravity 3.5-3.7 3.4-4.0 4.0-4.6 4.3-4.8 4.2-5.2 4.9-5.3 5.8-6.8 6.2-7.8 Unit Weight of Concrete (kg/m3) 2900-3200 2900-3350 3350-3700 3500-3700 3350-4150 3850-4150 4100-5150 4650-6100

Unit Weight (kg/m3) 2100-2250 2100-2400 2300-2550 2550-2700 2400-3050 2900-3200 3200-4150 3700-4650

Goethite Limonite Barite Illmenite Magnetite Hematite Ferrophosphorus Steel

a

N N N N N N S S

N, natural material; S, synthetic material