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Published on Sep 27, 2018

Abstract
Now-a-days there are so many technologies involved
in the recent development of concrete. Of these,
Cellular Lightweight Concrete (CLC) is one of the
recent emerging technology in making concrete. By
using this type of concrete, we have found so many
advantages when compared to the normal
conventional concrete. This paper mainly focused on
making cellular light weight concrete based on flyash.
Fly ash is considered as one of the waste industrial
product that cannot be easily disposed. It solves the
problem of disposal of flyash and at the same time it
reduces the cost of the construction. Therefore, flyash
based CLC is considered as environment friendly
sustainable material produced with least energy
demand. This paper also focused on the innovative
idea of using glass as a partial replacement of cement
in fly ash based cellular light weight concrete.

The density is considerably reduced by using fly ash

based cellular lightweight concrete than normal
concrete and at the same time, the strength is not
affected by appropriate design mix. When we use this
type of concrete we achieve large volume by less
amount of concrete. The manufacturing process of
this type of concrete does not involve any high cost
techniques. Manufacturing process of CLC is similar
to normal concrete and in this additionally foam
generating machine is used. We are committed to
expanding and sharing the knowledge, experience
and techniques of cellular light weight concrete, and
to promoting its ever wider use.

Introduction
Fly Ash Based Cellular Light Weight
Concrete
• It is a version of lightweight concrete that is
produced like normal concrete under ambient
conditions. It is produced by initially making a slurry
of Cement +Sand + Fly Ash (constituting 26% - 34 %
content) + water,

• A cellular concrete is a lightweight product

consisting of Portland cement, cement-silica,
cement-pozzolan, lime-pozzolan, lime-silica pastes or
pastes containing blends of these gradients and
having homogeneous void or cell structure, attained
with gas-forming chemicals of foaming agents.

• In cellular lightweight concrete, the density can be

controlled by the introduction of gas or foam by foam
generator.

• CLC is an air-cured lightweight concrete with fly ash

as a major ingredient that can be produced at large
project sites just like traditional concrete, utilising
equipment and moulds normally used for traditional
concreting.

• It is especially suitable in India for low-rise load

bearing constructions and for partitioning work in
multistorey blocks.

• Fly Ash as a new additional constituent in its

manufacture. Fly ash can constitutes more than 25%
(ranging between 26% to 33%) of the solid material
constituents of CLC mixes for different density
outputs.

• Fly-ash- a nuisance waste product from thermal

power plants - as an over 25 % constituent material.
This CLC can be produced in a density range of 400
kg/m3 to 1,800 kg/m3, with high insulation value and
a 28-day cube crushing strength of up-to 275
kg/cm2.

• It is not only found a productive use of a waste

industrial product, but incorporation of fly ash also
saves nearly 40% on cement content, otherwise
needed for the corresponding Cement and Sand only
mixes, thereby also leading to substantial reduction in
the cost of manufacture.

• Normally the density of the cellular light weight

concrete ranges from 400 kg/m3 to 1,800 kg/m3

• Cellular Light Weight Concrete based housing is fire

proof, termite proof, thermally insulated, sound proof,
environment friendly.

Density Range:
This Cellular Lightweight Concrete (CLC) can be
produced in a wide range of densities from 400
kg/m3 to 1,800 kg/m3 to suit different applications: -

• The lower densities of 400 –600 kg/m3 are ideal for

thermal insulation applications. CLC’s fire, termite,
water-proof-ness, termite-resistance, very low water
absorption and environment friendliness. This range is
also used in laying sound insulating layer over
structural slabs of intermediate floors in high-class
hotels and institution buildings to minimise
transmission of noise between lower and upper
floors. It can also be used as a filling in depressions in
bathrooms or other floors due to up-stand beams etc.
It make a far superior alternative to the commonly
used Thermocole, glasswool, woodwool etc.

• The medium density range 800-1000 kg/m3 is

utilized for making pre- cast blocks for non-load-
bearing walling masonry in framed structures. The
size of blocks for the party/external walls may be
500x250x200 mm and the internal partition blocks
may be 500x250x100 mm nominal size, although any
desired size as per requirements, may be produced.

• The high density range from 1200kg/m3 (Crushing

strength 65 kg/cm2) to 1800 kg/m3 (Crushing
strength 250 kg/cm2) is structural grade material
utilized for:-

(a) In-situ casting of structural (load-bearing) walls

and roofs of low rise individual or group housing
schemes.

(b) Manufacture of reinforced structural cladding or

partitioning panels.

(c) Making pre-cast blocks (500x250x200/100 mm) for

load- bearing walling masonry for low rise buildings.

Manufacturing Process
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The manufacturing process of cellular light weight

concrete involves the following steps:

(a) providing a mixture of slurry of Cement, Sand, Fly

Ash and water.

(b) pouring the mixture into a form or mold of the

intended concrete product

(c) curing the poured mixture;

(d) demolding the concrete product; and

(e) utilizing the concrete product.

The typical mix for a 1.000 kg/m³ density CLC to be

used in blocks is as follows (to produce 1 m3):

Wet density = 1.179 kg/m3

Total volume (submerged in water) 1.000 liters (= 1

m³)

Content of air in concrete approx. = 43%

Content of Fly-Ash = 33%

• In this process, first the wet mix slurry consists of fly

ash, cement, sand and water is either poured or
pumped into assembled moulds of blocks or
formwork of reinforced structural elements or poured
onto flat roofs for thermal insulation or for filling of
voids.

• The second way is to introduce gas or foam to the

concrete mix to produce cellular lightweight concrete.

• The foam produced using Foam Generator is stable

for a time duration far beyond the final setting time of
Cement, thereby creating permanent voids in the
finally hardened mass thus imparting lightness.

• The entrapped air bubbles are very fine in size and

segregated from each other, because of which the
water absorption of the material is less.

• The foam imparts free flowing characteristics to this

slurry due to ball bearing effect of foam bubbles,
enabling it to easily flow into all corners. It levels and
compacts in the moulds/forms by itself, without
requiring any kind of external vibration or compaction

Innovative Idea: (Use of Glass

in CLC)
• It is a method of manufacturing cellular lightweight
concrete using ground glass as a partial replacement
for Portland cement in the mixtures.

• This method also incorporates a method of making

cellular lightweight concrete including mixing these
materials in a mixer to form a thick, viscous slurry
which will be foamed and cured at room or elevated
temperatures.

• The mixture of CLC using ground glass comprises

cement, ground glass, cement substitute, lime, fiber,
foaming agent and water.

• The ground glass may include ground mixed waste

glass, flat glass, window glass and mixtures thereof.

Specifications of the ingredients:

• The impurities in mixed waste glass, such as metals,
plastics, paper, and wood should be separated.
Waste glass should be ground to a particle size
passing through a number 30 sieve.

• Lime may include hydrated lime, quicklime or lime

kiln dust. The lime kiln dust should contain free CaO
not less than 50%. The lime concentration in the form
of CaO should be up to 15% by weight of the
mixture.

• Cement substitutes can be divided into two

categories:

(i) reactive materials

(ii) non-reactive materials

(i) Reactive materials have cementitious or pozzolanic

properties and can also be supplementary cementing
materials including ground blast furnace slag, coal fly
ash, natural pozzolans, ground steel slag and silica
fume.

(ii) Non-reactive materials do not have any

cementitious or pozzolanic properties and usually act
as inert fillers in hardened cement pastes or concrete.
Typical examples include: silica flour, crushed stone
dust, saw dust and/or pulverized ceramics.

Objectives of Using Glass in CLC:

• able to produce very stable cellular lightweight
concrete mixtures during the foaming or aeration
process.

• able to produce light color cellular lightweight

concrete mixtures that can be easily tinted by adding
proper pigments.

• able to provide applications which can use

inexpensive recycled materials.

Advantages of CLC:
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• CLC being the typical concrete, it keeps gaining

strength with time, so long as some moisture is
available in the surroundings. It is therefore as
weatherproof, termite resistant, fireproof and durable
as any other concrete.

• Cellular Lightweight Concrete is an environment

friendly sustainable material produced with least
energy demand.

• Moreover CLC consumes a waste industrial product

- Fly Ash - as one of its basic constituent materials
thereby helping to reduce environmental pollution.

• It substitutes use of burnt clay bricks, which are

wasting precious agricultural soil and need energy for
baking and kiln smoke vitiate the atmosphere.

• Thinner walls in the case of CLC result in higher

Carpet/Plinth area ratio (106% to 107%) in
comparison to brick alternative.

• CLC produced at project site saves energy

expended in baking bricks, as also energy spent in
transporting bricks/ dense concrete blocks to site of
work. CLC blocks being lighter than bricks or Dense
Concrete blocks save on labour deployed for on-site
handling, masoning, cutting and filling chases etc.

• The capital investment in production of CLC is far

far less (in fact less than 0.05%) than the investment
needed for producing Aerated Autoclaved Concrete.
Only one low investment Foam Generator needs to be
added to Concrete making establishment.

• Being integrally cast as a lightweight reinforced

shell, these cellular light weight concrete structures
are highly resistant to earthquake shocks or storms in
coastal areas.

• Cellular light weight concrete, even in the structural

grade densities, is nearly three times thermally more
efficient than brick or mud walls. Therefore even
thinner walls of CLC are better thermal comfort than
single bricks/ dense concrete block walls.

• Being industrialized system the speed of

construction is very fast and the work can be
executed mostly with the help of unskilled labour.

• Production of CLC is cheaper than normal concrete

since fly ash, available free constitutes over 25% of
its raw material contents.

• Better strength to weight ratio .

•Flecks
Reduction of dead Inc.
Systems, load resulting in saving of steel &
cement and reduction in foundation size.

• Better Acoustics and thermal insulation (Air

conditioning requirement is considerably reduced).

• Saving in consumption of mortar and Higher Fire

Rating.

• Resistance to fungus, vermin and rot .

Strength:
The 28 day compressive strength of cellular light
weight concrete varies from 18 Mpa to 20 Mpa
depending upon the density of the mix.

The flexural strength of is, in general, between 1/5

and 1/3 of the compressive strength .

CLC can be produced in a density range of 400

kg/m3 to 1,800 kg/m3, with high insulation value and
a 28-day cube crushing strength of up-to 275
kg/cm2.

Application
The wide range in densities and consequently their
different thermal and structural properties, make CLC
equally suitable for use: -

As reinforced load-bearing in-situ walls and roofs in

Low Rise Buildings.

Even block-work (made from pre-cast blocks

produced at the project site or obtained from a pre-
casting plant) can also be used for load-bearing low
rise constructions.

Non load-bearing internal or external walls in High

Rise Buildings.

Thermal Insulation of building roofs and walls &

roofs of cold storage.

Filling of depressions in Toilets, floors etc.

CONCLUSION
The deliberations above conclusively establish, that
air cured fly-ash based Cellular light-weight concrete
to be a far superior alternative to factory made
aerated concrete or manmade light-weight aggregate
blocks. This CLC is even a better alternative to
ordinary clay bricks for walling masonry. The long
term stability at low temperatures and potential
corrosive effects on cellular light weight concrete
must be completely understood. The influence of
admixtures and aggregates on strength of CLC is of
particular interest and is currently being investigated.
Moreover, CLC has other diverse applications and
properties, some of which cannot be offered by the
conventional alternatives Above all, it is an
environment friendly and energy efficient material,
which is the need of the day. It is therefore, no
surprise that more and more builders are
progressively opting for this material in their
constructions

REFERENCES
1. Cellular Lightweight Concrete (Rotating Tower)-Dr.
Arch. David Fisher

2. Www.Google.com

3. Www.Youtube.com

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